Factory Workshop Manual
Make
Dodge
Model
Grand Caravan
Engine and year
V6-201 3.3L (1994)
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This manual was submitted by
Anonymous
Date
1st January 2018
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio
Control Relay > Component Information > Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations > Page 10
Keyless Entry Module: Diagrams
Remote Keyless Entry Module Connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Service and Repair > Programming Module
Keyless Entry Module: Service and Repair Programming Module
PROGRAMMING RKE MODULE
The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is
interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be
programmed into the Body Control Module (BCM). A functional key fob transmitter is required to
program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan
tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm
(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds
(maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC
button. A single chime will sound to verify that the
RKE module is set to receive the new VAC.
(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30
seconds or when ignition switch is turned OF{ the RKE
module will end the programming mode. A single chime will sound to verify that the RKE module
will no longer receive additional VAC(s).
(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation
using each key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Service and Repair > Programming Module > Page 13
Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement
REMOVAL
(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.
INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 18
Keyless Entry Module: Diagrams
Remote Keyless Entry Module Connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair > Programming Module
Keyless Entry Module: Service and Repair Programming Module
PROGRAMMING RKE MODULE
The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is
interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be
programmed into the Body Control Module (BCM). A functional key fob transmitter is required to
program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan
tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm
(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds
(maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC
button. A single chime will sound to verify that the
RKE module is set to receive the new VAC.
(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30
seconds or when ignition switch is turned OF{ the RKE
module will end the programming mode. A single chime will sound to verify that the RKE module
will no longer receive additional VAC(s).
(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation
using each key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair > Programming Module > Page 21
Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement
REMOVAL
(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.
INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 25
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay >
Component Information > Locations
ABS Main Relay: Locations
Fig. 19 Engine Compartment Wiring
Mounted on left fender side shield.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay >
Component Information > Locations > Page 30
ABS Main Relay: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect wiring harness electrical connectors from relays,
then remove screw securing relay assembly to left front inner fender. 3. Reverse procedure to
install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump
Relay > Component Information > Locations
Brake Fluid Pump Relay: Locations
Fig. 19 Engine Compartment Wiring
Mounted on left fender side shield.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Diagrams
ABS Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Diagrams > Page 37
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 information from the wheel speed sensors to control the anti-lock
brake system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Diagrams > Page 38
Electronic Brake Control Module: Service and Repair
1. With ignition switch in Off position, disconnect both battery cables and remove battery, then
remove battery tray from vehicle. 2. Remove Controller Anti-lock Brake (CAB) from battery tray
support bracket. 3. Loosen bolt securing 60-way connector to CAB, then disconnect connector from
CAB by pulling straight out. Do not twist connector. 4. Remove CAB with its mounting bracket from
vehicle. 5. Reverse procedure to install, noting the following:
a. Ensure ignition switch is still in Off position before connecting 60-way connector to CAB. b.
Torque connector bolt to 38 inch lbs. and CAB assembly mounting bolt to 14 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Locations
Radiator Fan Relay: Locations
Radiator Fan Relay is located in the Power Distribution Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 43
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 44
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions
Radiator Fan Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 47
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 48
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 49
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 50
Radiator Fan Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 51
Radiator Fan Relay: Electrical Diagrams
Air Conditioning System (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 52
Air Conditioning System (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 53
Air Conditioning System (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 54
Air Conditioning System (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 55
Radiator Fan System With Heater
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 56
Heater System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Description and Operation
Blower Motor Relay: Description and Operation
Chrysler does not use a Blower Motor Relay for these Year/Make/Model Vehicles.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Compressor Clutch Relay: Locations
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 64
In Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 65
Compressor Clutch Relay: Description and Operation
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 66
In Power Distribution Center
PURPOSE
Supplies ground path for A/C compressor clutch.
OPERATION
Controlled by A/C or defrost switch (inside vehicle) and Powertrain Control Module (PCM). Relay
receives battery voltage from radiator fan relay , (A/C relay will not energize unless the radiator fan
relay is energized).
When A/C or defrost is selected, (turned ON), inside vehicle, and low and high pressure switches
are closed, PCM receives an A/C ON signal. PCM then supplies relay ground.
If PCM senses Wide Open Throttle (WOT) or low idle speed condition, it removes relay ground,
discontinueing A/C clutch engagement.
PCM delays activation of A/C relay for a specific period after engine start-up.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
RH Side Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component
Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module >
Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Speedometer Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module >
Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 82
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module >
Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 83
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B
> Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Speedometer Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo.
Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B
> Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 89
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B
> Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 90
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations
Backup Lamp Relay: Locations
In Power Distribution Center
The Backup Lamp Relay is located in the Power Distribution Box.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 95
Power Distribution Center
As shown, the Backup Lamp Relay is in the bottom row center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 96
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions
Daytime Running Lamp Control Unit: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 102
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 103
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 104
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 105
Daytime Running Lamp Control Unit: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 106
Daytime Running Lamp Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 107
Daytime Running Lamp Control Unit: Electrical Diagrams
Daytime Running Lamp Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 108
Fog Lamp System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations
Turn Signal Relay: Locations
Relay Block
Combination flasher relay plugs into the lower left corner of the relay bank located to the left of the
fuse block. Remove the lower steering wheel column cover for access.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 132
Micro Relay Block: Locations Power Distribution Center Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 133
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 134
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 135
Micro Relay Block: Locations Micro Relay Block and Relay Bank Location
Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of
instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions
Micro Relay Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 138
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 139
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 140
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 141
Micro Relay Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 142
Micro Relay Block: Connector Views
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 143
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 144
Micro Relay Block: Electrical Diagrams
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 145
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 146
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay
Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 147
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle
Repeatedly
Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle
Repeatedly > Page 158
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly
Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 164
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > Page 165
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions
Body Controller: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 168
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 169
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 170
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 171
Body Controller: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 172
Body Controller: Connector Views
Body Control Module Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 173
Body Control Module Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 174
BCM Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 175
BCM Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and
ID > BCM Identification
Body Controller: Application and ID BCM Identification
There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument
cluster.
- The other supports the electronic instrument cluster.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and
ID > BCM Identification > Page 178
Body Controller: Application and ID Glossary of Terms
BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and
ID > Page 179
Body Controller: Description and Operation
PURPOSE
The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these
systems.
- Is the only module that has the capability of providing both bias and termination on the CCD bus
system.
- Is used to store odometer information displayed in the electronic instrument cluster.
OPERATION
The body systems are monitored by individual control modules, which send information about their
operation to the body control module over the CCD (Chrysler Collision Detection multiplex system)
bus. Through the CCD bus, information about the operation of vehicle components and circuits is
relayed to the appropriate module(s).
- Each module receives the same information about a component or circuit as another module
does.
- This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
BODY SYSTEM COVERAGE:
- Automatic Door Locks
- Compass/mini-trip Module
- Courtesy Lamps
- Electronic Instrument Cluster (EIC)
- Electro/mechanical Instrument Cluster
- Mechanical Instrument Cluster (MIC)
- Illuminated Entry
- Remote Keyless Entry (RKE)
- Intermittent Wipers
- Liftgate Release
NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board
diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications
(CCD) Bus/Testing and Inspection for diagnosis and repair procedures.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
GLOSSARY OF TERMS
BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and
Inspection > Component Tests and General Diagnostics
Body Controller: Component Tests and General Diagnostics
Diagnostic Notes - Read First
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
NOTE: These diagnostics are based on the failure condition or symptom being present at the time
of diagnosis.
TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
Be careful when performing electrical tests to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components and will sometimes set a second code, making
diagnosis of the original problem more difficult.
WARNINGS:
- When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
- When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests.
To efficiently diagnose CCD bus problems follow these six steps:
1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5.
Repair the Isolated Problem 6. Verify Proper Operation
ROAD TESTING
Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and
to verify the repair.
CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled.
- During the test drive, do not try to read the scan tool screen while in motion.
- Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant
available to operate the scan tool.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
Description of On-Board Diagnostics
A scan tool is required to read body system trouble codes. However, not all body system problems
have a corresponding trouble code.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and
Inspection > Component Tests and General Diagnostics > Page 182
Body Controller: Scan Tool Testing and Procedures
If the scan tool Does Not Power Up;
Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link
connector cavity 16).
If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully
charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and
Inspection > Page 183
Body Controller: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge
- Voltmeter
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > High Altitude Kit - Installation
Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation
NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993
SUBJECT: High Altitude Kits
MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
SYMPTOM/CONDITION:
The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st
page of the Starting and Operating section) that can be used if the owner changes his residence
from an area of low altitude to one of high altitude. These kits are required by the EPA for some
1994 federally certified AS body vehicles to comply with high altitude emissions standards. The
high altitude kit will have no effect on vehicle performance or driveability.
DIAGNOSIS:
Vehicles for which these kits are available have the following statement on the Vehicle Emission
Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE
OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at
the owner's expense.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label.
1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All
Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in
the "Parts Required" section of this bulletin.
2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of
the dash panel that the new labels will be attached to.
3. Attach the new VECI label on top of the original label.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > High Altitude Kit - Installation > Page 188
4. Type in the required information on the Authorized Modification label (P/N 4275086) as
illustrated, and attach next to the VECI label.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations > Component Locations
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations > Component Locations > Page 191
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 194
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 195
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 196
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 197
Powertrain Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 198
Powertrain Control Module 60 Way Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 202
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 203
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 206
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 207
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 208
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 209
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 210
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Power Distribution Center (Relay Locations)
Fuel Pump Relay Socket
Fuel pump relay is located in LH side of engine compartment in the power distribution center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 217
Fuel Pump Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded
by the Powertrain Control Module (PCM).
OPERATION
The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM
is receiving reference signals from the distributor pick-up.
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater
element.
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 218
Fuel Pump Relay: Testing and Inspection
NOTE: The relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the component being operated.
- Terminal number 86 is connected to a switched (+) power source.
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 222
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 223
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 226
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 227
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 228
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 229
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 230
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 238
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 239
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 240
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 241
Ignition Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations
Air Bag Control Module And Body Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control
Module 4 Way Connector
Air Bag Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control
Module 4 Way Connector > Page 248
Air Bag Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control
Module 4 Way Connector > Page 249
Airbag System Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer
Safety Information
Supplemental Restraint System (SRS) Control Module: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer
Safety Information > Page 252
Supplemental Restraint System (SRS) Control Module: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer
Safety Information > Page 253
Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings
CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF"
and the battery is disconnected. Failure to do so could damage the module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 254
Supplemental Restraint System (SRS) Control Module: Description and Operation
OPERATION
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the air bags. The total time between determining to deploy and deflation of the air bag is 1/10th of a
second.
SELF DIAGNOSTIC FUNCTIONS
Whenever the ignition key is turned to the "RUN" or "START" position, the air bag control module
(ACM) performs a lamp check by turning the AIR BAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM
has checked the system and found it to be free of discernible malfunctions. The air bag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the air bag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The
ACM provides diagnostic information about the air bag system to the technician through the DRB
via the CCD bus.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection >
Component Tests and General Diagnostics
Supplemental Restraint System (SRS) Control Module: Component Tests and General Diagnostics
GENERAL INSPECTION
A visual inspection consists of physically looking for possible cause of a malfunction. A careful and
thorough visual inspection of components may quickly identify malfunction cause and eliminate
need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with
diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are
properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag
warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go
out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case
and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for
damage and terminals for deformities. 7. Remove air bag module as outlined under Component
Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified
tester. 9. Check air bag pad cover for dents, cracks or deformities.
10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for
damage, terminals for deformities and harness for binds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 257
Supplemental Restraint System (SRS) Control Module: Scan Tool Testing and Procedures
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Page 258
Supplemental Restraint System (SRS) Control Module: Service and Repair
AIR BAG CONTROL (ACM), REPLACE
1. Disarm air bag system as outlined under Air Bag System Disarming and Arming.
See: Body and Frame/Interior Moulding / Trim/Dash Panel/Air Bag(s) Arming and
Disarming/Service and Repair
2. Remove screws attaching lower console to instrument panel support bracket. 3. Remove upper
console attaching screws behind cup holder, then slide console to rear and up to remove. 4.
Disconnect ACM wiring and remove module, then remove ACM mounting screws. 5. Reverse
procedure to install and tighten screws to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 263
In Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 264
Starter Relay: Testing and Inspection
Fig 4 Starter Relay Tests
1. Remove starter relay from relay center. 2. Perform testing procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
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> Jun > 95 > A/T - Poor Shift Quality > Page 275
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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> Jun > 95 > A/T - Poor Shift Quality > Page 276
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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> Jun > 95 > A/T - Poor Shift Quality > Page 277
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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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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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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080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
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080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 285
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
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080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 286
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693
> Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
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> Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 291
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
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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: > 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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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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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 298
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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Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 299
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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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 301
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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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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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
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Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 307
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 308
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 313
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 325
Power Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 326
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
329
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
330
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
331
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
332
Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
333
Control Module: Connector Views
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
334
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
335
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
336
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
337
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
338
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
339
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
340
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
341
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
342
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
343
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
344
Transmission Control Schematic
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information > Page
347
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 (V6-201 3.3L (1994))
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 > General Information > Page
348
Control Module: Description and Operation Electronic Transmission Controller Operation
LOCATION
The EATX control module is located under the hood, in a potted, die cast aluminum housing with a
sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and output speeds over 140 times a second and
responding to each new reading.
- This provides the precise friction element control needed to make smooth clutch-to-clutch shifts
for all gear changes.
As with most automatic transaxles, all shifts involve releasing one element and applying a different
element.
- In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to
ensure that it does not have excess capacity; the apply element is filled until it begins to make the
speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate
of speed change until the shift is complete.
The key to providing excellent shift quality is precision;
EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the
amount of that slip is typically less than a total of 20 degrees.
LEARNING
To achieve that precision, the EATX control module learns the characteristics of the particular
transaxle that it is controlling.
- It learns the release rate of the releasing element and the apply time of the applying element.
- It also learns the rate at which the apply element builds pressure sufficient to begin making the
speed change.
- This method achieves more precision than would be possible with exacting tolerances. It can also
adapt to any changes that occur with age or environment, for example, altitude, temperature,
engine output, etc.
KICKDOWN SHIFTING
For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate
at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing
element reapplies to maintain that speed until the apply element is filled.
This provides quick response since the engine begins to accelerate immediately and a smooth
torque exchange since the release element can control the rate of torque increase.
This control can make any power train feel more responsive without increasing harshness.
SUMMARY
Adaptive controls respond to input speed changes They compensate for changes in engine or
friction element torque and provide good, consistent shift quality for the life of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 351
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.
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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
Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control
Relay > Page 356
Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay
Transmission Relay Location
The Transmission Relay is located in LH side of engine compartment in the Power Distribution
Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Relay > Page 357
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 358
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page
363
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Relay Block
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning
Light ON Continuously
Wheel Speed Sensor: Customer Interest ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning
Light ON Continuously > Page 385
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions
Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number
81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 391
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 392
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 393
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 394
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 395
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 396
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 397
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 398
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 399
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 400
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 401
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 402
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 403
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 404
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 405
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 406
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 407
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 408
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 409
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 410
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 411
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 412
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 413
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 414
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 415
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
052294 > Dec > 94 > ABS - Warning Light ON Continuously
Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 420
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis
Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed
Sensor Diagnosis
NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994
SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis
MODELS: 1993 - 1994
(AA) Spirit/Acclaim/LeBaron Sedan
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1994 (AP) Shadow/Shadow Convertible/Sundance
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS.
DISCUSSION:
Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection
have been and are continuing to be tested. An unusually large number of these wheel speed
sensors are being found to have no defects.
The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles:
The diagnostic manual MUST be followed without exception. No shortcuts should be used during
the diagnostic procedure.
All diagnostic work Must begin with test "1A".
All diagnostic work MUST end with "VER-1A".
Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as
preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications
Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications
NO.: 05-17-93 Rev. A
GROUP: Brakes
DATE: Dec. 22, 1993
SUBJECT: Left Front Wheel Speed Sensor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991-1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE
SYSTEM (ABS).
DISCUSSION:
On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel,
depending upon the model year. The difference between the two parts is the length of the wiring,
and they should not be interchanged.
P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this
part is used on prior model year vehicles the wiring may become damaged.
P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a **
later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to
the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring.
This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts
catalog bulletin is being developed and the parts catalog will be revised at a later date.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions
Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number
81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 434
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 435
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 436
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 437
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 438
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 439
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 440
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 441
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 442
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 443
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 444
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 445
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 446
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 447
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 448
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 449
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 450
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 451
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 452
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 453
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 454
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 455
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 456
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 457
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 458
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis
Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed
Sensor Diagnosis
NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994
SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis
MODELS: 1993 - 1994
(AA) Spirit/Acclaim/LeBaron Sedan
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1994 (AP) Shadow/Shadow Convertible/Sundance
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS.
DISCUSSION:
Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection
have been and are continuing to be tested. An unusually large number of these wheel speed
sensors are being found to have no defects.
The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles:
The diagnostic manual MUST be followed without exception. No shortcuts should be used during
the diagnostic procedure.
All diagnostic work Must begin with test "1A".
All diagnostic work MUST end with "VER-1A".
Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as
preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications
Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications
NO.: 05-17-93 Rev. A
GROUP: Brakes
DATE: Dec. 22, 1993
SUBJECT: Left Front Wheel Speed Sensor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991-1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE
SYSTEM (ABS).
DISCUSSION:
On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel,
depending upon the model year. The difference between the two parts is the length of the wiring,
and they should not be interchanged.
P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this
part is used on prior model year vehicles the wiring may become damaged.
P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a **
later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to
the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring.
This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts
catalog bulletin is being developed and the parts catalog will be revised at a later date.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 467
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 (V6-201 3.3L (1994))
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
1. Raise and support vehicle, then remove wheel and tire assembly.
Fig. 252 Front Wheel Speed Sensor 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.
NOTE: 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 5 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 470
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, noting the following: a. Torque sensor mounting bolt to 5 ft. lbs. b.
Torque U-bolt nuts to 65 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications
Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications
NOTE: For information on how this type of sensor operates SEE, Powertrain
Management/Computers and Control Systems/Coolant Temperature Sensor/Description and
Operation.
NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM).
COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
-20° F ...................................................................................................................................................
....................................... 4.70 V
-10° F ...................................................................................................................................................
....................................... 4.57 V
0° F ......................................................................................................................................................
...................................... 4.45 V
10° F ....................................................................................................................................................
....................................... 4.30 V
20° F ....................................................................................................................................................
....................................... 4.10 V
30° F ....................................................................................................................................................
....................................... 3.90 V
40° F ....................................................................................................................................................
....................................... 3.60 V
50° F ....................................................................................................................................................
....................................... 3.30 V
60° F ....................................................................................................................................................
....................................... 3.00 V
70° F ....................................................................................................................................................
....................................... 2.75 V
80° F ....................................................................................................................................................
....................................... 2.44 V
90° F ....................................................................................................................................................
....................................... 2.15 V
100° F ..................................................................................................................................................
........................................ 1.83 V
110° F ..................................................................................................................................................
........................................ 1.57 V
120° F ..................................................................................................................................................
........................................ 1.25 V
HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
110° F ..................................................................................................................................................
........................................ 4.20 V
120° F ..................................................................................................................................................
........................................ 4.00 V
130° F ..................................................................................................................................................
........................................ 3.77 V
140° F ..................................................................................................................................................
........................................ 3.60 V
150° F ..................................................................................................................................................
........................................ 3.40 V
160° F ..................................................................................................................................................
........................................ 3.20 V
170° F ..................................................................................................................................................
........................................ 3.02 V
180° F ..................................................................................................................................................
........................................ 2.80 V
190° F ..................................................................................................................................................
........................................ 2.60 V
200° F ..................................................................................................................................................
........................................ 2.40 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 477
210° F ..................................................................................................................................................
........................................ 2.20 V
220° F ..................................................................................................................................................
........................................ 2.00 V
230° F ..................................................................................................................................................
........................................ 1.80 V
240° F ..................................................................................................................................................
........................................ 1.62 V
250° F ..................................................................................................................................................
........................................ 1.45 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 478
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 479
Coolant Temperature Sensor/Switch (For Computer): Locations
Ignition Coil And Coolant Temperature Sensor Location
Sensor mounted under ignition coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Diagram Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Diagram Information and Instructions > Page 482
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Diagram Information and Instructions > Page 483
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Diagram Information and Instructions > Page 484
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Diagram Information and Instructions > Page 485
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Diagram Information and Instructions > Page 486
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Diagram Information and Instructions > Page 487
Coolant Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Page 488
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
LOCATION
The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the
thermostat housing.
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Page 489
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Coolant Temperature Sensor Resistance Test
1. With key off, disconnect connector from coolant temperature sensor.
2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows;
- 700 to 1,000 Ohms at approximately 200°F (operating temperature).
- 7,000 to 13,000 ohms at approximately 70°F, (room temperature).
3. If resistance is not within specifications, replace sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Page 490
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Ignition Coil And Coolant Temperature Sensor Location
REMOVAL
1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical
connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant
temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6.
Remove sensor from engine.
INSTALLATION
1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor.
3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12
Nm (105 in lbs) torque. 5. Connect electrical connector to coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 496
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 497
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 498
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 499
Temperature Sensor (Gauge): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 500
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 501
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.
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and
Inspection
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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. Remove stop lamp switch, then inspect for continuity between terminal No. 5 and No. 6 with
plunger released. Continuity Should exist. 2. Inspect for continuity between terminal No. 1 and No.
2 with plunger depressed. Continuity Should exist. 3. Inspect for continuity between terminal No. 3
and No. 4 with plunger depressed. Continuity Should exist. 4. If continuity is not as specified, then
stop lamp switch is out of adjustment or defective.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 081694 > Apr > 94 >
Speed Control Switch - Loose/Rattles
Cruise Control Switch: Customer Interest Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 081694 > Apr > 94 >
Speed Control Switch - Loose/Rattles > Page 514
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 081694
> Apr > 94 > Speed Control Switch - Loose/Rattles
Cruise Control Switch: All Technical Service Bulletins Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 081694
> Apr > 94 > Speed Control Switch - Loose/Rattles > Page 520
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > Page 521
Cruise Control Switch: Testing and Inspection
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.
Fig. 108 Speed Control Continuity Chart
Fig. 8 Speed Control Connector Terminal Identification
3. Results should be obtained according to the chart. If these results are not obtained, replace
switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > Page 522
Cruise Control Switch: Service and Repair
1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two
screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting
switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to
install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 531
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 537
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 544
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 545
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 546
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 547
Oil Pressure Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 548
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Locations
Air Conditioning Switch: Locations
Heater A/C Controls
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Front Of Engine Compartment, Front Of Radiator
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
Engine Compartment Wiring
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Cut-Off
Switch
Low Pressure Sensor / Switch: Locations Low Pressure Cut-Off Switch
The Low pressure cut-out switch (LPCO) is located on the expansion valve. The expansion valve is
silver in color.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Cut-Off
Switch > Page 564
Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch
The Electronic Cycling Clutch Switch (ECCS) is located on the A/C expansion valve at the rear of
engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 565
Low Pressure Sensor / Switch: Description and Operation
The Low Pressure Cut-Off (LPCO) Switch monitors the refrigerant gas pressure on the suction side
of. the system. The LPCO is located on the expansion valve, and the expansion valve is silver in
color. The LPCO turns off voltage to the compressor clutch coil when refrigerant gas pressure
drops to levels that could damage the compressor. The LPCO is a sealed factory calibrated unit. It
must be replaced if defective.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 566
Low Pressure Sensor / Switch: Testing and Inspection
Low Pressure Cut-off Switch
The work area temperature must not be below 10°C (50°F) to test the compressor clutch. circuit
1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise
hood and disconnect LPCO switch connector boot. 3. Using a suitable jumper wire, jump across
the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling
clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge
set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, LPCO switch will
complete the clutch circuit. If the low pressure gauge reads below 172 kPa (25 psi), the system is
low on refrigerant charge or empty due to a leak.
6. Install connector boot on switch and repeat step number 3. If the clutch does not engage,
replace the. LPCO switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure
Cut-Out Switch Replacement
Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement
Low Pressure Cut-Off Switch (LPCO)
REMOVAL AND INSTALLATION
WARNING: The refrigeration system must be completely empty before proceeding with this
operation.
1. Disconnect the boot like wire connector at the cut-off switch. 2. Using a sender unit type socket,
remove the switch from the expansion valve.
To insure an adequate seal on the switch, use a small amount of thread sealing tape. Reverse the
preceding steps.
Evacuate and charge the system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure
Cut-Out Switch Replacement > Page 569
Low Pressure Sensor / Switch: Service and Repair Low Pressure Cycling Clutch Switch
Replacement
Electronic Cycling Clutch Switch Combo Valve (ECCS)
REMOVAL AND INSTALLATION
1. Disconnect the 3 pin connector at the ECCS. 2. Remove 4 mm hex bolt from side of expansion
valve. 3. Slip the capillary tube from the well on the expansion valve. The capillary-tube-well is filled
with a special temperature conductive grease. Save
this special grease and reuse it when installing the new switch.
To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions
Dimmer Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 575
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 576
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 577
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 578
Dimmer Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 579
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar
Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar
Lamp - Flickers/Locks Cycle Repeatedly > Page 588
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94
> Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94
> Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 594
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Component Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Component Locations > Page 597
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions
Fuel Gauge Sender: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 602
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 603
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 604
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 605
Fuel Gauge Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 606
Fuel Pump System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 607
Fuel Gauge Sender: Description and Operation
Fuel Pump MODULE And Connector TYPICAL
The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the
tank change.
As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or
further away from, the sensor signal terminal.
The further away the sensor pickup is, the higher the resistance across the sensor is.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 608
Fuel Gauge Sender: Testing and Inspection
SENDING UNIT TEST
NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check
the gauge -- check for a defective sending unit, sending unit wiring, or body control module.
Sending units and wiring can be checked by grounding the connector leads at the sending unit.
With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to
read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump
module connector.)
The following procedure tests the resistance of the level sensor. It does not test the sensor circuit.
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fluid level changes.
1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the
ground terminal of the fuel pump module connector. (The
middle terminal and the terminal farthest away from the middle terminal.)
2. Move the float lever to the full position and empty position and note the resistance at both points.
3. Replace the sensor if the resistance is not within the specified values.
- Sensor Full Position 8 ohms maximum
- Sensor Empty Position 96.5 - 108.0 ohms
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 609
Fuel Gauge Sender: Service and Repair
Fuel level sensor replacement procedure is included in Fuel Pump Module service.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 615
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 616
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 617
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 618
Backup Lamp Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service
Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service
NO.: 08-67-93
GROUP: Electrical
DATE: Dec. 31, 1993
SUBJECT: Stop Light Switch Wiring Connector Service
MODELS:
1995 (PL) Neon
1994 (AA) Spirit/Acclaim/LeBaron Sedan
1994 (AJ) LeBaron Convertible
1994 (AP) Shadow/Sundance
1994 (AS) Caravan/Voyager/Town & Country
1994 (BR) Ram Pickup
1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
1994 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
When servicing the stop light switch or wiring connector, the stop light switch wiring connector may
be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage
the insulator wedge or the switch itself.
REPAIR PROCEDURE:
This bulletin involves removing the stop light switch with wiring connector attached as an assembly
before disconnecting the wiring connector.
1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the
switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket.
2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring
connector from the stop light switch insulator, Figure 1.
NOTE:
DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING
ON THE WIRING MAY RESULT IN OPEN CIRCUITS.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service
> Page 623
3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector
insulator and the wedge and prying up while pushing the wedge out towards the wire harness,
Figure 2.
4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge
into the connector, then insert the wiring harness connector into the stop light switch assembly and
finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the
switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the
adjustment procedure in the appropriate service manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Technical Service Bulletins > Page 624
Stop Lamp Switch: Locations
Brake Switch
Sensor mounted on brake pedal support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions
Stop Lamp Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 627
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 628
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 629
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 630
Stop Lamp Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 631
Stop Lamp Switch: Electrical Diagrams
Vehicle Speed Control & Stop Lamp Switch SH-57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 632
Vehicle Speed Control & Stop Lamp Switch SH-58
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Page 633
Stop Lamp Switch: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then
remove switch assembly. 3. Reverse procedure to install. If switch adjustment required, proceed as
follows:
a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull brake
pedal back until it will go back no further. Switch will ratchet backward into correct position.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Service and Repair
Combination Switch: Service and Repair
The multi-function switch includes the turn signal, headlight beam select and windshield wiper
switches. If any of these switches are found defective, the entire multi-function switch must be
replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3.
On all models, remove upper and lower steering column covers, then remove multi-function switch
tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then
remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Technical Service Bulletins > Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly
Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Technical Service Bulletins > Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 645
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar
Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar
Lamp - Flickers/Locks Cycle Repeatedly > Page 651
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 07-06-98 > Nov > 98 >
Cooling Module Fan - Vibrates/Comes Loose
Fan Blade: All Technical Service Bulletins Cooling Module Fan - Vibrates/Comes Loose
NO: 07-06-98
GROUP: Cooling
DATE: Nov. 20, 1998
SUBJECT: Cooling Module Fan Nut
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(International Market)
DISCUSSION:
Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling
module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and
the engine may overheat.
A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to
address this condition and should be used for repair any time this condition is experienced and the
fan blade is not damaged.
The cooling fan blade and motor were balanced as an assembly at the time of manufacture and
must be properly oriented to minimize vibration. The cooling fan blade can be installed on the
cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates
excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft
180 degrees from the first installation position.
The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Component Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Component Locations > Page 664
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions
Headlight Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 672
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 673
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 674
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 675
Headlight Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 676
Headlight Switch: Connector Views
Headlamp Switch Connector (Part 1 Of 3)
Headlamp Switch Connector (Part 2 Of 3)
Headlamp Switch Connector (Part 3 Of 3)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 677
Headlight Switch: Electrical Diagrams
Headlamp Switch (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 678
Headlamp Switch (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 679
Headlight Switch: Service and Repair
The headlamp switch is part of the left pod switch assembly. 1. Fabricate a 3/16 inch diameter
metal rod approximately 10 inches long. Bend 1 1/2 inches on both ends 90°. 2. Place fabricated
tool in hole right of switch in cluster bezel below the pod switch assembly, then depress lower tab
and pull switch free of lower
tab.
3. Move tool upward right side of switch to top tab, then pull tab down and pull switch out of bezel.
4. Disconnect wire connector. 5. To install, connect wire connector and push switch into until tabs
lock.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 689
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations >
Component Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations >
Component Locations > Page 692
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 695
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 696
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 697
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 698
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 699
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 700
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 701
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 702
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications
Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications
NOTE: For information on how this type of sensor operates SEE, Powertrain
Management/Computers and Control Systems/Coolant Temperature Sensor/Description and
Operation.
NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM).
COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
-20° F ...................................................................................................................................................
....................................... 4.70 V
-10° F ...................................................................................................................................................
....................................... 4.57 V
0° F ......................................................................................................................................................
...................................... 4.45 V
10° F ....................................................................................................................................................
....................................... 4.30 V
20° F ....................................................................................................................................................
....................................... 4.10 V
30° F ....................................................................................................................................................
....................................... 3.90 V
40° F ....................................................................................................................................................
....................................... 3.60 V
50° F ....................................................................................................................................................
....................................... 3.30 V
60° F ....................................................................................................................................................
....................................... 3.00 V
70° F ....................................................................................................................................................
....................................... 2.75 V
80° F ....................................................................................................................................................
....................................... 2.44 V
90° F ....................................................................................................................................................
....................................... 2.15 V
100° F ..................................................................................................................................................
........................................ 1.83 V
110° F ..................................................................................................................................................
........................................ 1.57 V
120° F ..................................................................................................................................................
........................................ 1.25 V
HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
110° F ..................................................................................................................................................
........................................ 4.20 V
120° F ..................................................................................................................................................
........................................ 4.00 V
130° F ..................................................................................................................................................
........................................ 3.77 V
140° F ..................................................................................................................................................
........................................ 3.60 V
150° F ..................................................................................................................................................
........................................ 3.40 V
160° F ..................................................................................................................................................
........................................ 3.20 V
170° F ..................................................................................................................................................
........................................ 3.02 V
180° F ..................................................................................................................................................
........................................ 2.80 V
190° F ..................................................................................................................................................
........................................ 2.60 V
200° F ..................................................................................................................................................
........................................ 2.40 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Electrical Specifications > Page 707
210° F ..................................................................................................................................................
........................................ 2.20 V
220° F ..................................................................................................................................................
........................................ 2.00 V
230° F ..................................................................................................................................................
........................................ 1.80 V
240° F ..................................................................................................................................................
........................................ 1.62 V
250° F ..................................................................................................................................................
........................................ 1.45 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 708
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 709
Coolant Temperature Sensor/Switch (For Computer): Locations
Ignition Coil And Coolant Temperature Sensor Location
Sensor mounted under ignition coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Information > Diagrams > Diagram Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
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Information > Diagrams > Diagram Information and Instructions > Page 712
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.
Fusible Link Color Code
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Information > Diagrams > Diagram Information and Instructions > Page 713
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Information > Diagrams > Diagram Information and Instructions > Page 714
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 715
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Information > Diagrams > Diagram Information and Instructions > Page 716
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 717
Coolant Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Page 718
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
LOCATION
The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the
thermostat housing.
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Information > Diagrams > Page 719
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Coolant Temperature Sensor Resistance Test
1. With key off, disconnect connector from coolant temperature sensor.
2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows;
- 700 to 1,000 Ohms at approximately 200°F (operating temperature).
- 7,000 to 13,000 ohms at approximately 70°F, (room temperature).
3. If resistance is not within specifications, replace sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Diagrams > Page 720
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Ignition Coil And Coolant Temperature Sensor Location
REMOVAL
1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical
connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant
temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6.
Remove sensor from engine.
INSTALLATION
1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor.
3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12
Nm (105 in lbs) torque. 5. Connect electrical connector to coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Electrical Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 725
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations >
Component Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations >
Component Locations > Page 728
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 731
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 732
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
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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 > Page 733
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 734
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 735
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 736
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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737
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
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738
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Vacuum in Inches of Mercury MAP sensor Signal Voltage
.39 in Hg ..............................................................................................................................................
.............................. 4.90 V
3.34 in Hg ............................................................................................................................................
............................... 4.60 V
6.30 in Hg ............................................................................................................................................
............................... 3.60 V
9.25 in Hg ............................................................................................................................................
............................... 3.10 V
12.20 in Hg ..........................................................................................................................................
................................ 2.60 V
15.15 in Hg ..........................................................................................................................................
................................ 2.10 V
18.11 in Hg ..........................................................................................................................................
................................ 1.60 V
21.06 in Hg ..........................................................................................................................................
................................ 1.10 V
24.01 in Hg ..........................................................................................................................................
................................ 0.60 V
26.97 in Hg ..........................................................................................................................................
................................ 0.31 V
Condition .............................................................................................................................................
.................................. Expected Output Voltage
High Vacuum (Idle/Deceleration)
.............................................................................................................................................................
0.5 to 1.5 volts
Medium Vacuum (Cruise/Slight Acceleration)
......................................................................................................................................... 1.5 to 3.0
volts
Low Vacuum (Hard Acceleration/Mechanical Failure)
............................................................................................................................. 3.0 to 4.5 volts
NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Control Component Locations
Back Side Of Intake Plenum View
Sensor mounted on back side of intake plenum.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 744
Back Side Of Intake Plenum View
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Diagram Information and Instructions
Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 747
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 748
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 749
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 750
Manifold Pressure/Vacuum Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 751
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 752
MAP Sensor Circuit
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Page 753
Manifold Pressure/Vacuum Sensor: Description and Operation
LOCATION
Sensor mounted on intake plenum.
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts.
- Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Page 754
Manifold Pressure/Vacuum Sensor: Testing and Inspection
NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its
circuitry, refer to appropriate Diagnostic Chart. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
TO TEST THE MAP SENSOR ONLY:
1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary.
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition
switch ON, and the engine OFF. Output voltage
should be 4 to 5 volts.
3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle
speed condition. The voltage should drop to 1.5
to 2.1 volts.
4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness
condition. Repair as necessary.
5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage
should be approximately 5 volts (±O.5 V). 5
volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair
or replace the wire harness as necessary.
6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal
/ pin-4. Repair the wire harness if necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Page 755
Manifold Pressure/Vacuum Sensor: Service and Repair
MAP" Sensor
Removal
1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting
screws and remove sensor.
Installation
1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Oxygen Sensor: Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations
Oxygen Sensor: Component Locations
EGR Mounting
Sensor threaded into exhaust manifold, just above flange.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 761
Back Side Of Intake Plenum View
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 764
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 765
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 766
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 767
Oxygen Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 768
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 769
Oxygen Sensor: Electrical Diagrams
Oxygen Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 770
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling
and Exhaust/Engine/Tune-up and Engine
Performance Checks/Firing Order/Specifications
- If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered
O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 771
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 774
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 775
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
Oxygen Sensor And Connector
Oxygen Sensor Connector Identification And PINOUT
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground
(terminals 3 and 4), of the sensor electrical
connector.
3. Resistance should be between 5 and 7 ohms, if not replace the sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page
776
Oxygen Sensor: Service and Repair
Oxygen Sensor Location (Typical)
Oxygen Sensor Socket
WARNING: Avoid physical contact with hot exhaust components.
CAUTION: Do not pull on or cut sensor wires, when removing sensor.
CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL
1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket
YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly
tightening the
sensor before removal may ease removal.)
3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap.
INSTALLATION
1. If a new sensor is being used, verify that the threads are coated with anti-seize compound,
before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel
based anti-seize compound, (Loctite 771-64 or equivalent).
CAUTION: Do not use graphite or other anti-seize compounds.
3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or
Delayed Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 790
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 793
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 796
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 797
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
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Information and Instructions > Page 798
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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
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Information and Instructions > Page 799
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Information and Instructions > Page 800
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Information and Instructions > Page 801
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
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Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
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Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
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Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
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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 (V6-201 3.3L (1994))
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Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 814
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 (V6-201 3.3L (1994))
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 815
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 816
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.
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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
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 (V6-201 3.3L (1994))
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 822
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 (V6-201 3.3L (1994))
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 > Page 823
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 828
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 (V6-201 3.3L (1994))
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 829
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 (V6-201 3.3L (1994))
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 830
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 836
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 (V6-201 3.3L (1994))
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 837
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 840
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 841
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 844
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 847
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 850
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 (V6-201 3.3L (1994))
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 851
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component
Locations
Vehicle Speed Sensor: Component Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component
Locations > Page 856
Vehicle Speed Sensor: Connector Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 859
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 860
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 861
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 862
Vehicle Speed Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 863
Vehicle Speed Sensor: Electrical Diagrams
Vehicle Speed Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 864
Vehicle Speed Sensor: Description and Operation
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or
Delayed Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 879
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 882
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 885
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 886
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 887
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 888
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 889
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 890
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 891
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 892
Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 893
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 894
Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 900
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations >
Page 903
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 906
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 907
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 908
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 909
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 910
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 911
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 912
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 913
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 918
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations >
Page 921
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 924
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 925
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 926
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 927
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 928
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 929
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 930
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 931
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition
Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition
Cylinder Addition
NUMBER: 23-44-94D
GROUP: Body
DATE: Jun. 3, 1994
Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105
DISCUSSION:
A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle
security.
The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a
bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove
the screw.
The 1995 Dakota service manual was completed prior to this information being available to Service
Publications. The vehicles listed as 1994 models only, will have this information already in their
corresponding 1995 service manual.
DESCRIPTION OF CHANGES
Add Tamper Resistant Ignition Key Cylinder Info.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 937
8D - 37
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 938
8D - 38
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 939
8D - 39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 940
8D - 39A
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 946
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 947
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 948
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 949
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 950
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 951
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations
Impact Sensor: Locations
Located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of.
the center console.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Customer Safety Information > Page 957
Impact Sensor: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Page 958
Impact Sensor: Description and Operation
OPERATION
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of. the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Testing and Inspection > Component Tests and General Diagnostics
Impact Sensor: Component Tests and General Diagnostics
GENERAL INSPECTION
A visual inspection consists of physically looking for possible cause of a malfunction. A careful and
thorough visual inspection of components may quickly identify malfunction cause and eliminate
need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with
diagnostic testing. 1. On all models, turn ignition switch to On. 2. If air bag warning lamp does not
light, proceed with diagnostic testing. 3. If air bag warning lamp fails to go out after ten seconds,
proceed with diagnostic testing. 4. Check air bag control module (ACM) case and brackets for
dents, cracks or deformities. 5. Check ACM connectors and lock levers for damage and terminals
for deformities. 6. Remove air bag module as outlined under Component Service. 7. Never attempt
to measure circuit resistance of air bag module even with a specified tester. 8. Check air bag pad
cover for dents, cracks or deformities. 9. Check air bag module for dents, cracks or deformities.
10. Check hooks and connectors for damage, terminals for deformities and harness for binds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 961
Impact Sensor: Scan Tool Testing and Procedures
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Testing and Inspection
Clutch Switch: Testing and Inspection
Bosch & Nippondenso Starters
The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal
switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal
released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to
floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully
depressed, replace switch if it fails any test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition
Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition
Cylinder Addition
NUMBER: 23-44-94D
GROUP: Body
DATE: Jun. 3, 1994
Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105
DISCUSSION:
A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle
security.
The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a
bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove
the screw.
The 1995 Dakota service manual was completed prior to this information being available to Service
Publications. The vehicles listed as 1994 models only, will have this information already in their
corresponding 1995 service manual.
DESCRIPTION OF CHANGES
Add Tamper Resistant Ignition Key Cylinder Info.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 971
8D - 37
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 972
8D - 38
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 973
8D - 39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 974
8D - 39A
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 >
Feb > 94 > A/T - Engine Stalls On Takeoff
Neutral Safety Switch: Customer Interest A/T - Engine Stalls On Takeoff
NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994
SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear
MODELS:
1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town &
Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN
ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES
THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS,
OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED.
SYMPTOM/CONDITION:
While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector
lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the
neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test
when the transmission temperature is -16 F (-27 C) or colder.
DIAGNOSIS:
Determine if the ambient temperature could have been -16 F (-27 C) or colder when the
transmission lever was placed in a forward gear position.
Assure the shift selector is not binding and is adjusted correctly.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic
procedure manual, verify that all 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. If no codes are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4707123 Switch, Neutral/Start (Park/Neutral)
REPAIR PROCEDURE:
NOTE:
THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE
SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID.
This bulletin involves replacing the park/neutral position switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 >
Feb > 94 > A/T - Engine Stalls On Takeoff > Page 983
1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs.
(34 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: >
210294 > Feb > 94 > A/T - Engine Stalls On Takeoff
Neutral Safety Switch: All Technical Service Bulletins A/T - Engine Stalls On Takeoff
NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994
SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear
MODELS:
1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town &
Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN
ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES
THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS,
OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED.
SYMPTOM/CONDITION:
While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector
lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the
neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test
when the transmission temperature is -16 F (-27 C) or colder.
DIAGNOSIS:
Determine if the ambient temperature could have been -16 F (-27 C) or colder when the
transmission lever was placed in a forward gear position.
Assure the shift selector is not binding and is adjusted correctly.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic
procedure manual, verify that all 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. If no codes are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4707123 Switch, Neutral/Start (Park/Neutral)
REPAIR PROCEDURE:
NOTE:
THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE
SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID.
This bulletin involves replacing the park/neutral position switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: >
210294 > Feb > 94 > A/T - Engine Stalls On Takeoff > Page 989
1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs.
(34 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > Page 990
Neutral Safety Switch: Locations
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
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 (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 993
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 994
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 995
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 996
Neutral Safety Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Page 997
Neutral Safety Switch: Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Page 998
Neutral Safety Switch: Testing and Inspection
The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract
codes.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Page 999
Neutral Safety Switch: Service and Repair
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations
Overdrive Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 1005
Overdrive Off Switch (8 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1017
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 (V6-201 3.3L (1994))
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 1018
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 (V6-201 3.3L (1994))
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 1019
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1025
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 (V6-201 3.3L (1994))
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 1026
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1031
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 (V6-201 3.3L (1994))
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 1032
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 (V6-201 3.3L (1994))
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 1033
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1039
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 (V6-201 3.3L (1994))
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 1040
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1043
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 1044
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
1047
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1050
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1053
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 (V6-201 3.3L (1994))
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 1054
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1063
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
1068
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 (V6-201 3.3L (1994))
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
1069
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 (V6-201 3.3L (1994))
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
1070
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1076
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1081
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 (V6-201 3.3L (1994))
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 1082
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 (V6-201 3.3L (1994))
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 1083
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 (V6-201 3.3L (1994))
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 1084
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor
Connector
Input Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor
Connector > Page 1087
Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1088
Transmission Speed Sensor: Description and Operation
Three pressure switches incorporated in an assembly with the solenoids identify solenoid
application.
Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds.
Position switch indicates manual shift lever position.
Engine speed, throttle position, temperature, etc., are also observed.
- Some of these signals are read directly from the engine control sensors; others are read from a
multiplex circuit with the powertrain control module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1089
Transmission Speed Sensor: Testing and Inspection
INPUT (TURBINE) SPEED SENSOR INSPECTION
1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals 1 and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the input speed sensor.
OUTPUT SPEED SENSOR INSPECTION
1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals I and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the output speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1090
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Diagrams > Diagram Information and Instructions
Power Window Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1099
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1100
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1101
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1102
Power Window Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1103
Power Window Switch: Electrical Diagrams
Overhead Console W/O Mini-Trip Computer (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1104
Overhead Console W/O Mini-Trip Computer (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams > Diagram Information and Instructions
Washer Fluid Level Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1110
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1111
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1112
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1113
Washer Fluid Level Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1114
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1115
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
The multi-function switch includes the turn signal, headlight beam select and windshield wiper
switches. If any of these switches are found defective, the entire multi-function switch must be
replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3.
On all models, remove upper and lower steering column covers, then remove multi-function switch
tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then
remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Diagrams
Wiper Switch: Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Diagrams > Page 1122
Rear Wiper Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Diagrams > Page 1123
Wiper Switch: Testing and Inspection
1. Place pod switch in the Off position.
Intermittent Wiper Pod Switch
2. Check for continuity between terminals A6 and A4. If continuity is not indicated, replace switch.
3. Place pod switch in the Max Delay position (left end of variable resistor). 4. Check for continuity
between terminal A7 and terminals A5, A3 and B3. If continuity is not indicated, replace pod switch.
5. Check resistance between terminals A1 and B3. Resistance should measure 210,000-390,000
ohms. If not, replace the pod switch. 6. Place switch in the Min Delay position (right end of variable
resistor). 7. Check for continuity between terminal A7 and terminals A5, A3 and B3. 8. Check
resistance between terminals A1 and B3. Resistance should measure 350-650 ohms. 9. When the
slide is moved from Max to Min Delay, or opposite. Continuity between terminal A7 and terminals
A5, A3 and B3 should remain
constant. If not, replace switch.
10. Resistance between terminals A1 and B3 will decrease as the control is moved from Max to
Min Delay, or increase when moved from Min to Max
Delay. If not, replace switch.
11. Place switch in the Lo position, then check for continuity between terminals A4 and B3. If
continuity is not indicated, replace pod switch. 12. Place switch in Hi position, then check for
continuity between terminals A2 and B3. If continuity is not indicated, replace switch. 13. Check for
continuity between terminals B3 and B4, when the front washer button is depressed. If not, replace
switch. 14. Check for continuity between terminals B2 and B5 when the rear wiper switch is in the
On position (indicator lamp will illuminate only when the
headlamps are on). If continuity is not indicated, replace switch.
15. Check continuity between terminals B1 and B5 when the rear washer button is depressed. If
continuity is not indicated, replace the switch. 16. Two switch illuminating bulbs are fed by terminal
B5 (ground) and B6 (power).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment
Specifications
Alignment: Specifications Front Alignment Specifications
Caster, Degrees ..................................................................................................................................
.................................................................... +1.3 [01] Camber, Degrees ............................................
..............................................................................................................................................................
.... 0.3 Toe-In, Inch ..............................................................................................................................
..................................................................................... 1/16 Ball Joint Wear ......................................
..............................................................................................................................................................
........... [03]
[01] -- Reference angle only, not adjustable.
[03] -- Refer to Ball Joint Inspection in Front Steering & Suspension section.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment
Specifications > Page 1129
Alignment: Specifications Rear Alignment Specifications
Caster, Degrees ..................................................................................................................................
.................................................................................. -- Camber, Degrees ..........................................
..............................................................................................................................................................
...... -0.2 Toe-In, Inch ...........................................................................................................................
....................................................................................... 0 [01] Ball Joint Wear ..................................
..............................................................................................................................................................
................ [04]
[01] -- Toe-out when vehicle is backed onto alignment rack is toe-in when driving.
[04] -- Refer to Ball Joint Inspection in Rear Steering & Suspension section.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment
Alignment: Service and Repair Front Alignment
Adjustment
CASTER
The caster angle on these vehicles cannot be adjusted.
Fig. 1 Camber Adjustment
CAMBER
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.
Fig. 2 Toe-in Adjustment
TOE-IN
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment >
Page 1132
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.
Preliminary Inspection
1. Tires are at recommended pressure, are of equal size and have approximately the same wear
pattern 2. Check front wheel and tire assembly for radial runout and inspect lower ball joints and
steering linkage for looseness. 3. Check front and rear springs for sagging or damage. 4. 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.
5. Prior to each alignment reading, vehicle should be bounced an equal number of times from
center of the bumper alternating first from rear, then
front, and releasing at bottom of down cycle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment >
Page 1133
Alignment: Service and Repair Rear Alignment
FWD MODELS
Fig. 3 Shim Installation For Toe-out (FWD)
Fig. 4 Shim Installation For Toe-in (FWD)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment >
Page 1134
Fig. 5 Shim Installation For Positive Camber (FWD)
Fig. 6 Shim Installation For Negative Camber (FWD)
Alignment adjustment is made by adding .010 inch shims between spindle mounting surface and
axle casting. Each shim equals wheel change by 0.3.°
When recording rear toe-in (vehicle backed onto alignment rack) remember to reverse sign
convention. Install alignment shims as follows; 1. Raise and support vehicle, then remove wheel. 2.
Remove brake drum, then loosen four brake assembly and spindle mounting bolts enough to allow
clearance for shim installation. Do not remove
mounting bolts.
3. Install shims as shown. No more than 2 shims on each spindle should be used to bring
alignment within acceptable range.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Specifications > Page 1143
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through
Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable,
inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform
minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES
MINIMUM AIRFLOW TEST IDLE SPEED
ODOMETER READING IDLE SPEED
Less than 1000 miles 525-875 RPM
More than 1000 miles 575-875 RPM
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications > Page 1147
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 (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Fuel Pressure Release Procedure - Typical
WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even
when the engine is OFF.
1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3.
Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose,
tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this
hose to
the fuel rail service port. Fuel pressure should bleed off into container.
5. Perform necessary fuel system service procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks
and Indicators > System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift
At Low Speed/Speedo. Fluctuates
Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift
At Low Speed/Speedo. Fluctuates > Page 1170
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift
At Low Speed/Speedo. Fluctuates > Page 1171
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates
Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 1177
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 1178
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Page 1179
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Page 1180
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
Purpose
Transfer electrical current from the distributor to individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1183
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables
must be released from inside the distributor cap.
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic
converter. Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an
open circuit or other damage.
INSPECTION
Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully
seated, and the nipples and spark plug covers should be in good condition.
Covers should fit tightly on the coil, distributor cap towers and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
RESISTANCE TEST
Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
Remove cable from spark plug.
Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables
must be removed from the spark plugs.
Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside
the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance
shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower
and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all
spark plug cables in same manner.
To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not
remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove
the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the
cable. Also, check for a loose connection at the tower or for a faulty coil.
Inspect coil tower for cracks or carbon tracking.
Secondary Ignition Cable Resistance Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten
minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
SPARK PLUG CABLES
1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not
remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the
ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure
probes make good contact.
Resistance should be within tolerance.
4. If the resistance is not within tolerance, remove cable at cap tower and check the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1184
5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in
same manner.
COIL TO DISTRIBUTOR HIGH TENSION CABLE
1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the
cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of
cable. 4. If resistance is not within tolerance, replace the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap Specifications
Spark Plug: Specifications Gap Specifications
NOTE: 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.
Spark Plug Gap ...................................................................................................................................
............................... 1.2 to 1.3 mm (0.048 to 0.053 in)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap Specifications > Page 1189
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
....................................................... 28 Nm (20 ft-lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1190
Spark Plug: Description and Operation
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for
spark plug diagnosis.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1193
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1194
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1195
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1196
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1197
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1198
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1199
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
PROCEDURE
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Page 1200
Spark Plug: Adjustments
Setting Spark Plug Electrode Gap
Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the
ground -- center electrode.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Service and Repair > Replacement Notes
Spark Plug: Service and Repair Replacement Notes
TIP: Always keep plugs in the order they were removed. Any plug that looks different from other
plugs indicates a problem in that cylinder.
NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and
Inspection/Procedures
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Service and Repair > Replacement Notes > Page 1203
Spark Plug: Service and Repair Removal and Installation
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
REMOVAL
1. Spray compressed air around spark plug to prevent foreign material from entering combustion
chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back
in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR:
- Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION
1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Cylinder Compression Pressure 100 psi
NOTE: No more than 25% variance between cylinders.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1207
Compression Check: Service Precautions
COMPRESSION TESTING
When performing a compression test, remove the fuel pump relay fuse and disconnect power to
the ignition. This will stop fuel flow to the injectors and prevent engine from starting.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1208
Compression Check: Testing and Inspection
PROCEDURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. 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. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For
Direct Ignition System (DIS) disconnect the coil connector.
5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage.
Record this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689
kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem
in the cylinder in question. The recommended compression pressures are to be used only as a
guide to diagnosing engine problems. An engine should not be disassembled to determine the
cause of low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16.
Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test
vehicle as a final test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Adjustments
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters, no adjustment is necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys
Drive Belt: Customer Interest Serpentine Drive Belt - Comes Off Pulleys
NO.: 07-02-94 Rev. A
GROUP: Cooling
DATE: Dec. 23, 1994
SUBJECT: Serpentine Drive Belt Comes Off Pulleys
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES
VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
**1992 - 1995 (ES) Chrysler Voyager (European Market)**
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of
its pulleys by snow coming in between the belt and the pulleys.
DIAGNOSIS:
Determine the road conditions the driver of the vehicle was encountering at the time the serpentine
belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are
properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor
in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley
attachment problem has been corrected, perform the following repair procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves attaching a shield to the power steering pump and the power steering pump
bracket that prevents snow from coming in between the serpentine belt and the power steering
pump pulley.
1. Re-install the serpentine drive belt or replace with a new belt if damaged.
2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the
engine block.
NOTE:
ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING
BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT
OFF. DO NOT BREAK THE TAB OFF.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys > Page 1220
3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield)
goes over the stud on the back of the power steering pump and the other mounting hole is aligned
with the hole of power steering pump bracket from which the bolt was removed in step 2.
4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m).
5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque
to 30 - 50 ft.lbs. (40.7 - 67.8 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
07-20-15-95 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys
Drive Belt: All Technical Service Bulletins Serpentine Drive Belt - Comes Off Pulleys
NO.: 07-02-94 Rev. A
GROUP: Cooling
DATE: Dec. 23, 1994
SUBJECT: Serpentine Drive Belt Comes Off Pulleys
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES
VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
**1992 - 1995 (ES) Chrysler Voyager (European Market)**
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of
its pulleys by snow coming in between the belt and the pulleys.
DIAGNOSIS:
Determine the road conditions the driver of the vehicle was encountering at the time the serpentine
belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are
properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor
in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley
attachment problem has been corrected, perform the following repair procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves attaching a shield to the power steering pump and the power steering pump
bracket that prevents snow from coming in between the serpentine belt and the power steering
pump pulley.
1. Re-install the serpentine drive belt or replace with a new belt if damaged.
2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the
engine block.
NOTE:
ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING
BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT
OFF. DO NOT BREAK THE TAB OFF.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys > Page 1226
3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield)
goes over the stud on the back of the power steering pump and the other mounting hole is aligned
with the hole of power steering pump bracket from which the bolt was removed in step 2.
4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m).
5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque
to 30 - 50 ft.lbs. (40.7 - 67.8 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
07-20-15-95 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1227
Drive Belt: Specifications
Belt tension is controlled automatically by the dynamic tensioner.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > With A/C
Fig. 34 Serpentine Drive Belt Routing
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > With A/C > Page 1230
Drive Belt: Diagrams Without A/C
Fig. 34 Serpentine Drive Belt Routing
This image shows an air conditioning compressor.
The OE does not provide an image for accessory belt routing without A/C.
This article is included here to provide the accessory drive belt routing for a non-air conditioned
vehicle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1231
Drive Belt: Description and Operation
The accessory drive system utilizes two different style of drive belts. The conventional V-belt and
the Poly-v belt are used to drive the generator, air conditioning compressor, power steering pump
and water pump. Satisfactory performance of these belts depends on belt condition and proper belt
tension. Belt tensioning should be performed with the aid of a Burroughs gauge special tool
C-4162, or equivalent. Because of space limitations in the engine compartment, the use of the
gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain
access to the drive belts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1232
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1233
Drive Belt: Adjustments
PROPER BELT TENSION
Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt
tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because
of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the
vehicle on a hoist and the remove the splash shield to gain access to the drive belts.
BELT TENSION GAUGE METHOD
Use belt tensioning Special Tool Kit C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges
are not interchangeable.
For Conventional V-belts - affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the
belt tension for New or Used belt as prescribed in specifications.
For a Poly-V Belt - affix the Poly-V Burroughs gauge to the belt and then apply specified tension to
the belt as prescribed in specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation
Drive Belt: Service and Repair Removal and Installation
Fig. 6 Accessory Drive Belt
REMOVE/INSTALL
The Poly-V Drive belt is provided with a dynamic tensioner Fig. 6 to maintain proper belt tension.
To remove or install this belt:
1. Raise vehicle on hoist. 2. Remove right front splash shield. 3. Release tension by rotating the
tensioner clockwise Fig. 6. 4. Reverse above procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation > Page 1236
Drive Belt: Service and Repair Cleaning and Inspection
When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt
from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal. Any belt with cracks running along the rib must
be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Page 1237
Belt Tension Gauge C-4162
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 1247
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 (V6-201 3.3L (1994))
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 1248
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 (V6-201 3.3L (1994))
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 1249
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During
EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During
EMCC Shift > Page 1255
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > 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 1260
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > 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 1261
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > 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 1262
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During
EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During
EMCC Shift > Page 1268
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Fluid Drain and Refill > Page 1271
Fluid Filter - A/T: Service and Repair Fluid & Filter Change
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
and Repair
Fuel Pressure Release: Service and Repair
Fig 1 Intake Plenum Mounting Bolts
Fuel Pressure Release Procedure - Typical
WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even
when the engine is OFF.
1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3.
Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose,
tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this
hose to
the fuel rail service port. Fuel pressure should bleed off into container.
5. Perform necessary fuel system service procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair
Oil Filter: Service and Repair
CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install
tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is
reinforced by the base plate.
1. Using Tool C-4065, or equivalent, turn filter counterclockwise to remove from base. Properly
discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new
filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighter filter 1 turn or 20
Nm (15 ft. Lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair >
Page 1279
Oil Filter Wrench C-4065
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications
Refrigerant Filter: Specifications
The oil designated for this vehicle is ND8 PAG (polyalkalene glycol).
Front A/C
- Filter-Drier 15 ml (0.5 oz)
Dual A/C
- Filter-Drier 30 ml (1.0 oz)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hoses
Heater Hose: Service and Repair Heater Hoses
Review Safety Precautions and Warnings the in General Information section before proceeding
with this operation.
1. Drain engine cooling system.
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peal off heater hose. This method will require heater hose replacement.
To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hoses > Page 1289
Heater Hose: Service and Repair Underbody Plumbing
WARNING: THE ENGINE COOLING SYSTEM MUST BE RELIEVED OF ALL PRESSURE.
1. Drain the engine cooling system.
2. In the engine compartment, and disconnect two auxiliary rear heater hoses from the (front)
heater hose tee fittings.
3. Hoist the vehicle. Disconnect two push-together couplings from the auxiliary rear heater core
tubes protruding through the floor pan.
4. Remove four bolts and one pal nut holding the plumbing to the floor pan and lower the plumbing
from the vehicle.
To Install, Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > A/C Hose - Squeaking Noise
Hose/Line HVAC: Technical Service Bulletins A/C Hose - Squeaking Noise
NO: 24-02-94
GROUP: Heat & A/C
DATE: Jan. 14, 1994
SUBJECT: Squeak in Right Shock Tower Area
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right
shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in
the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn
through, a squeak may occur under driving conditions. Inspect the hose and bracket area and
relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Page 1294
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Removal and Installation
Hose/Line HVAC: Service and Repair Removal and Installation
REMOVAL (1) Recover A/C system. (2) Remove upper generator bracket. See: Starting and
Charging/Charging System. (3) Remove ground wire at cowl.
(4) Remove expansion valve plate and bolt (Fig.50. (5) Remove liquid line from expansion valve.
(6) Remove wire connector at pressure transducer. (7) Remove liquid line mounting bracket at right
frame rail. (8) Using access slot between radiator crossmember arid grille, loosen liquid line
mounting plate at filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to remove line. The replacement Tine is a two-piece
assembly.
INSTALLATION (1) To install, reverse preceding operation. Replace all O-rings. Install two-piece
line in place of original part. Assemble line halves after it is installed
on vehicle.
(2) Evacuate and recharge A/C system.
SUCTION LINE
REMOVAL (1) Recover A/C system.
(2) Remove suction line mounting nut at compressor (Fig. 51). (3) Remove upper generator
bracket. See: Starting and Charging/Charging System (4) Remove ground wire at cowl.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Removal and Installation > Page 1297
(5) Remove expansion valve line plate nut (Fig.52). (6) Remove suction line mounting bracket. (7)
Remove suction line.
INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and
recharge A/C system.
DISCHARGE LINE
REMOVAL (1) Recover A/C system
(2) Remove discharge line mounting nut at compressor (Fig. 53).
(3) Remove discharge line at the top fitting on the condenser (Fig. 54).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Removal and Installation > Page 1298
INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and
recharge A/C system. (3) Perform HVAC Control calibration and test procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Removal and Installation > Page 1299
Hose/Line HVAC: Service and Repair Rear Air Conditioning Lines
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE
FOLLOWING OPERATION.
1. Hoist the vehicle. Disconnect two tube-fittings from the engine compartment plumbing.
2. Remove the bolt from the unified plumbing block (left side of car, outboard of rail, forward of fuel
tank).
3. Carefully pull refrigerant line assembly down (take care NOT to scratch the sealing surface with
the tube pilots). Remove and discard the
aluminum gasket and cover unit sealing surface to prevent contamination.
4. Remove two screws holding plumbing to the fuel tank support and left-side support rail (near
muffler support bracket).
5. Remove two screws holding the plumbing to the floor pan.
6. Disconnect the parking brake system at hook above muffler and the cable connection near the
support rails.
7. Fish the nylon tubing and unified plumbing block above the muffler support member.
8. Lower the plumbing from the vehicle.
9. Measure the residual oil in the under body plumbing out of each end of the plumbing. The
lowside (larger diameter line) has a check valve that can
restrict oil flow from the tube-fitting to the unified plumbing end of the hose. Measure clean R134a
PAG refrigerant oil to be returned to the refrigerant system.
INSTALL
1. Protect the plumbing ends from scratches. If plumbing is new, do not remove the shipping caps
until joining together.
2. Reverse the preceding steps from the REMOVAL procedure.
3. New gaskets and O-rings are required for installation. The O-rings must be covered with clean
refrigerant oil prior to installation.
4. Connect the tube-fittings to the engine compartment under body plumbing. Avoid misalignment
of the threads (cross threading) and tighten to 200
in-lbs
5. Remove the shipping cap from the plumbing side sealing surface and verify that the aluminum
gasket is present.
6. Carefully align the pilot tubes of the plumbing line block into the unit (take care not to scratch the
sealing surface).
7. Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolt to 200 +/- 30 in
lbs (23 +/- 3 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1304
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1305
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine - Coolant Recommendations > Page 1310
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Page 1311
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1320
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1321
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1322
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Fluid - A/T: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 1327
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift >
Page 1333
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
1338
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 (V6-201 3.3L (1994))
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
1339
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 (V6-201 3.3L (1994))
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
1340
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Fluid - A/T: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts >
Page 1345
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page
1351
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transaxle/Transmission - Automatic
See TSB 21-010-06 4/14/2006
CAPACITY, Initial Refill*: All with transverse engine............................................................................
......................................................................................3.8 Liters 4.0 Quarts
All with longitudinal engine...................................................................................................................
............................................4.2 Liters 4.5 Quarts
*With the engine at operating temperature, shift transmission through all gears. Check fluid level in
PARK and add fluid as needed
1993 Grand Caravan adding or replace, Mopar ATF Plus 4 type 9602.
Initial Refill Capacity
Automatic..............................................................................................................................................
..........................................................................AP‡ CAPACITY, Initial Refill*: All with transverse en
gine.......................................................................................................................................................
...........3.8 Liters 4.0 Quarts
All with longitudinal engine...................................................................................................................
............................................4.2 Liters 4.5 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 only when AP is not available only for "Topping off"
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1354
Fluid - A/T: Fluid Type Specifications
See TSB 21-010-06 4/14/2006
ATF Plus 4 Type 9602 Oil Type
................................................................................................................................................. Mopar
(R) ATF Plus 4 Type 9602, Or Equivalent.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check > Page 1357
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check > Page 1358
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications
Fluid - Differential: Specifications
TYPE ...................................................................................................................................................
........................................................... 80W-90 GL-5
CAPACITY, Refill:
All with longitudinal engine
..........................................................................................................................................................
0.9 Liters 2.0 Pints
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications
Engine Oil: Specifications
TYPE....................................................................................................................................................
...............................................................SG, SG/CD*
*Preferred with Turbo engine SG/CD required for 1993 Turbo engine.
CAPACITY, Refill: 3.3L Concorde, Intrepid, Vision
...................................................................................................................................................... 4.3
Liters 4.5 Quarts
3.5L, all ................................................................................................................................................
........................................... 4.8 Liters 5.0 Quarts
All others ..............................................................................................................................................
........................................... 3.8 Liters 4.0 Quarts
Capacity shown is without filter. When replacing filter, additional oil may be needed
All engine. above 0°F (-18°C)...............................................................................................................
.....................................................................10W-30* 2.5L Van, 3.5L & Turbo below 32°F (0°C)........
.........................................................................................................................................................5
W-30‡
Non-Turbo ex. 2.5L Van below 100°F (38°C).......................................................................................
........................................................................5W-30 *Preferred in all Turbo, 2.5L & 3.5L ‡Preferred
in all non-Turbo ex. 2.5L Van
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions >
Technician Safety Information
Engine Oil: Technician Safety Information
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID
PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED
ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR
HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN
RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR
DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions >
Technician Safety Information > Page 1367
Engine Oil: Vehicle Damage Warnings
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page
1368
Engine Oil: Description and Operation
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service
Grade SH or SH/CD.
SAE VISCOSITY
An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single
viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE
viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil
that is best suited to your particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. They are designated as
either ENERGY CONSERVING or ENERGY CONSERVING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been adopted to aid in the proper selection of
engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top
of engine oil cans.
ENGINE OIL ADDITIVES
In some instances, such as infrequent operation, short trip driving, and during break-in after a
major overhaul, addition of special materials containing anti-rust and anti-scuff additives are
beneficial.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page
1369
Engine Oil: Testing and Inspection
CHECKING OIL LEVEL
To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check
the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is
about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has
sat overnight. Checking the oil while the vehicle is on level ground, will improve the accuracy of the
oil level readings. Maintain the oil level between the MIN and MAX markings on the dipstick.
Adding one quart of oil when the reading is at the MIN mark will result in a MAX reading on these
engines.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page
1370
Engine Oil: Service and Repair
CHANGING ENGINE OIL
Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface
and turn engine off. 2. Hoist and support vehicle on safety stands. Refer. to Hoisting and Jacking
Recommendations. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5.
Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain
plug and gasket if damaged.
6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and
amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
R 134A Refrigerant - Leak Detection Systems
Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection Systems
NO.: 24-20-93
GROUP: Air Conditioning
DATE: Jul. 30, 1993
SUBJECT: R-134A Refrigerant Leak Detection
MODELS:
DISCUSSION:
Numerous R-134A leak detection units are on the market. Some units are better than others, and
keep in mind R-134A is more difficult to detect than R-12 because of R-134A's smaller molecular
structure. Listed below are the R-134A leak detection units currently approved by Chrysler:
HITECH Instruments models HI 300 TEL, HI 350, HI 400 NOVA TEL, and HI 450 NOVA.
Leybold Inficon models HLD4000 and D/TEC.
OTC/Yokogawa model H10N.
All Jeep/Eagle dealers were shipped R-134A equipment in March 1992 to be able to service the ZJ
products and Chrysler/Plymouth/Dodge dealers were shipped the same equipment in May 1993. A
HITECH Instruments, Model HI 300 TEL leak detector, was included in these equipment packages.
Use of any other R-134A leak detection equipment will lead to improper diagnosis, repeat repairs
and customer dissatisfaction. HITECH Instruments Models are available through Professional
Service Equipment.
Points to keep in mind when performing R-134A leak detection:
* Testing should be performed 5-7 minutes after A/C system has be turned off.
* The hood should be raised at least 5 minutes prior to performing leak detection. This is to help
ensure any accumulation of R-134A can dissipate and prevent detecting false leaks throughout the
engine compartment.
* The probe should be moved at a rate of 1-2 inches per second and no more than 1/2 inch from
the surface being checked. DO NOT HOLD THE PROBE IN ONE LOCATION OR ALLOW THE
PROBE TO TOUCH ANY SURFACE OR LIQUID. Doing so may contaminate the probe and cause
false readings.
* Probe along the bottom side of the components because R-134A is heavier than air.
* Leak detector probes are very sensitive to contaminants. Do not expose probes to lubricants,
paint, welding and mastic fumes, vehicle fuel, exhaust or coolant, halogenated solvents,
chlorinated water or steam, dust, powder, or direct streams of R-12 or R-134A. Contaminants
cause false readings.
* Always follow the leak detector manufacturer's instructions very closely.
* A properly maintained and calibrated APPROVED LEAK DETECTOR is your best tool for
accurate leak detection and customer satisfaction.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
R 134A Refrigerant - Leak Detection Systems > Page 1375
Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection
NO.: 24-13-94
GROUP: Air Conditioning
DATE: Sep. 9, 1994
SUBJECT: R-134a Refrigerant Leak Detection
MODELS:
1994 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1994 - 1995 (AB) Ram Van/Ram Wagon
1994 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1994 - 1995 (AN) Dakota/Dakota Cab & Chassis
1994 (AP) Shadow/Sundance
1993 - 1995 (AS) Caravan/Voyager/Town & Country
1994 (BD) Laser/Talon (Midyear Change)
1994 - 1995 (BR) Ram Truck
1994 - 1995 (B7) Stealth
1994 - 1995 (B8) Colt Vista/Summit Wagon
1994 - 1995 (B9) Colt/Summit
1994 - 1995 (ES) Chrysler Voyager (Export Only)
1995 (FJ) Avenger/Sebring/Talon
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
1995 (PL) Neon
1993 - 1995 (SR) Viper
1994 - 1995 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
R-134a refrigerant leaks are more difficult to detect than R-12 because of the smaller molecular
structure. Listed below are the R-134a leak detection units currently approved by Chrysler and
SAE:
HITECH Instruments Models HI 300 TEL, H1350, HI 400 NOVA TEL, and Hi 450 NOVA
Leybold Inficon Models HLD4000 and D/TEC
OTC/Yokogawa Model H10N
NOTE:
LEAK DETECTOR PROBES ARE VERY SENSITIVE TO CONTAMINANTS. DO NOT EXPOSE
PROBES TO LUBRICANTS, PAINT, WELDING AND MASTIC FUMES, VEHICLE FUEL,
EXHAUST OR COOLANT, HALOGENATED SOLVENTS, CHLORINATED WATER OR STEAM,
DUST, POWDER, OR DIRECT STREAMS OF R-12 OR R134a. ANY TIME CONTAMINATION IS
VISUALLY PRESENT ON THE PROBE, OR THE PROBE IS SUSPECTED OF BEING NEAR A
CONTAMINANT, FOLLOW THE MANUFACTURERS RECOMMENDATION FOR CLEANING OR
REPLACING THE FILTER/SENSOR. ONLY A PROPERLY MAINTAINED LEAK DETECTOR WILL
PROVIDE ACCURATE LEAK DETECTION.
TECHNICIAN PROCEDURE FOR USING ELECTRONIC REFRIGERANT LEAK DETECTORS
FOR SERVICE OF MOBILE AIR CONDITIONING SYSTEMS
SAE Recommended Practice J1628
1. The electronic leak detector shall be operated in accordance with the equipment manufacturer's
operating instructions.
2. Leak test with the engine not in operation.
3. The air conditioning system shall be charged with sufficient refrigerant to have a gauge pressure
of at least 340 kPa (50 psi) when not in operation. At temperatures below 15~C (59~F), leaks may
not be measurable since this pressure may not be reached.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
R 134A Refrigerant - Leak Detection Systems > Page 1376
4. Take care not to contaminate the detector probe if the part being tested is contaminated. If the
part is particularly dirty, it should be wiped off with a dry shop towel or blown off with shop air. No
cleaners or solvents shall be used, since many electronic detectors are sensitive to their
ingredients.
5. Visually trace the entire refrigerant system and look for signs of air conditioning lubricant
leakage, damage, or corrosion on all lines, hoses, and components. Each questionable area
should be carefully checked with the detector probe, as well as all fittings, hose to line couplings,
refrigerant controls, service ports with caps off, brazed or welded areas, and areas around
attachment points and holddowns on lines and components.
6. Always follow the refrigerant system around in a continuous path so that no areas of potential
leaks are missed. If a leak is found, always continue to test the remainder of the system.
7. At each area checked, the probe should be moved around at a rate of no more than 25 to 50
mm/s (1 to 2 inches/second), and no more than 5 mm (1/4 in.) from the surface completely around
the position. Slower and closer movement of the probe greatly improves the likelihood of finding a
leak.
8. An apparent leak should be verified at least once by blowing shop air into the area of the
suspected leak, if necessary, and repeating the check of the area. In cases of very large leaks,
blowing out the area with shop air often helps locate the exact position of a leak.
9. Leak testing of the evaporator core while in the air conditioning module should be accomplished
by turning the air conditioning blower on high for a period of 15 seconds minimum, shutting it off,
then waiting for the refrigerant to accumulate in the case for time specified by 9.1, then inserting
the leak detector probe into the condensate drain hole if no water is present, or into the closest
opening in the heating/ventilation/air conditioning case to the evaporator, such as heat duct or vent
duct. If the detector alarms, a leak apparently has been found.
NOTE:
R134a REFRIGERANT IS HEAVIER THAN AIR AND WILL TEND TO STAY LOW IN THE A/C
MODULE.
9.1 The accumulation time shall be specified by the leak detector manufacturer in the instructions
included with the detector, or a minimum of 2 minutes.
10. Following any service to the refrigerant system of the vehicle, and any other service which
disturbs the refrigerant system, a leak test of the repair and of the service ports of the refrigerant
system should be done.
NOTE:
CURRENTLY THERE IS NO CHRYSLER APPROVED R-134A REFRIGERANT LEAK
DETECTION DYE AVAILABLE. USE OF AN UNAPPROVED DYE WILL CAUSE DAMAGE TO
THE A/C SYSTEM. AN APPROVED DYE WILL BE AVAILABLE IN THE NEAR FUTURE.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
A/C System
With Rear AC .......................................................................................................................................
....................................................... 1.420 kg (50 oz)
Without Rear AC ..................................................................................................................................
...................................................... 1.020 kg (36 oz)
Capacities
Capacities
Capacity
2.25 lb (US)
Capacities
Capacities
Capacity
3.25 lb (US)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1379
Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications
A/C Refrigerant Specifications
Refrigerant type
R134a
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
A/C System
When all air conditioning system is first assembled, all components (except the compressor) are
refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and components.
The evaporator, condenser, and filter-drier will retain a significant amount of oil, see below. When a
component is replaced, the specified amount of refrigerant oil must be added.
When the compressor is replaced, the amount of oil that is retained in the rest of the system must
be drained from the replacement compressor. When a line or component has ruptured and oil has
escaped, the compressor should be removed and drained. The filter-drier must be replaced along
with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining
components, can be measured and poured into the suction port of the compressor.
EXAMPLE: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1
oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil.
220 ml minus 90 ml = 130 ml (4.40 oz).
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND-8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................. 142 ml (4.73 oz)
- Filter-Drier .........................................................................................................................................
................................................... 15 ml (0.5 oz)
- Condenser .........................................................................................................................................
..................................................... 15 ml (0.5 oz)
- Evaporator .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Capacities
Capacities
Ounces Viscosity
4.73 oz (US) ND8 PAG
Polyalkaline Glycol
Capacities
Capacities
Ounces Viscosity
7.40 oz (US) ND8 PAG
Polyalkaline Glycol
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 1384
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil
The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, Polyalkylene Glycol
(PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils,
and should never be introduced to an R-134a refrigerant system.
Refrigerant oil will absorb any moisture it comes in contact with, including moisture in the air. The
oil container should be kept tightly capped until it is ready to be used. Then, cap the oil immediately
after using, to prevent contamination.
There are different PAG oils available, and each contains a different additive package. The
refrigerant oil designated for this vehicle is ND-8 PAG . Use only refrigerant oil of this same type to
service the refrigerant system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil
Charge Additions
Refrigerant Oil: Service and Repair Oil Charge Additions
It will not be necessary to check the oil level in the compressor or add oil unless there has been an
oil loss. Oil loss at the leak point will be evident by the presence of a wet, shiny surface around the
leak. If a leak is detected and the compressor must be removed, it is not necessary to discharge
the system unless the refrigerant lines will be removed for service. If the lines will be removed,
discharge system as outlined in "System Diagnosis/Evacuating the A/C System" and note the
following procedure:
1. Disconnect battery ground cable. 2. Loosen and remove drive belts and disconnect compressor
clutch wire lead. 3. Remove refrigerant lines from compressor. 4. Remove compressor attaching
nuts and bolts. 5. From suction port on top of compressor, drain refrigerant oil from compressor. 6.
Install replacement components. 7. Add system capacity minus the capacity of components that
have not been replaced. 8. Reverse procedure to install. 9. Evacuate and recharge system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil
Charge Additions > Page 1387
Refrigerant Oil: Service and Repair Purging Compressor
The compressor must be purged of air whenever it has been isolated from the system for service.
1. Install oil plugs or reconnect refrigerant lines and manual valves to compressor as needed.
2. Cap service access ports on both manual valves, then rotate low (suction) side service valve
counterclockwise to the back-seated position.
3. Rotate high (discharge) side manual valve to mid-position, then slightly loosen cap on high side
gauge port to allow refrigerant to force air out of compressor.
4. Back seat high side manual valve, then tighten gauge port cap.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision
Brake Bleeding: Technical Service Bulletins Brakes - Bendix ABS System Bleeding Procedure
Revision
NUMBER: 05-01-94
GROUP: Brakes
DATE: May 27, 1994
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1994 Town & Country, Caravan and Voyager Service Manual - Publication No.
81-370-4105
DESCRIPTION OF CHANGES
Bendix Antilock 4 Bleed Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision > Page 1392
5-76
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision > Page 1393
5-77
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision > Page 1394
5-78
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1397
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
Brake System Bleeding
The content of this article reflects the changes called out by TSB 05-01-94.
The base brake system must be bled anytime air is permitted to enter the hydraulic system.
However, anti-lock brake system components should only be bled if the hydraulic control unit has
been removed or if there is reason to believe that air has entered the unit. The ABS portion of the
braking system must be bled separately. Under most circumstances, only the base brake system
will require bleeding. If the anti-lock brake system must be bled, proceed as follows:
1. Bleed base brake system, then remove battery, battery tray, support bracket and acid shield.
2. Using suitable jumper cables, reconnect battery to vehicle battery cables, then connect DRB
scan tool to diagnostic connector. Use extreme
caution to avoid arcs and shorts against vehicle body when battery is connected through cables.
3. Using DRB, ensure Controller Antilock Brake (CAB) has no stored diagnostic trouble codes. 4.
Bleed modulator primary check valve circuit, then the secondary check valve circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1398
Fig. 242 Primary Check Valve Circuit Bleed Screw Location
Fig. 243 Secondary Check Valve Circuit Bleed Screw Location
a. Connect clear bleed tube to check valve circuit bleed screw, then place other end of tube in a
clear glass container partially filled with clean
brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening check valve circuit bleed screw one full
turn.
c. When brake pedal bottoms, tighten bleed screw, then release pedal. Do not release pedal until
bleed screw is tight. d. Repeat procedure until brake fluid flowing through tube appears bubble-free
and clean, then torque modulator assembly secondary bleed screw
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1399
to 80 in. lbs. Do not remove bleed hose before screw is tight.
5. Bleed modulator primary sump circuit as follows:
Fig. 244 Primary Sump Circuit Bleed Screw Location
a. Connect clear bleed tube to primary sump circuit bleed screw, then place other end of tube in a
clear glass container partially filled with clean
brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening primary sump circuit bleed screw one
full turn.
c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit." Right front
and left rear solenoids will fire alternately for
approximately five seconds.
d. Continue to select "Primary Circuit" on DRB until brake fluid flowing through bleed tube is
bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears
bubble-free, repeat procedure. f.
Torque primary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube
from screw. Do not release pedal until bleed screw is tight.
6. Bleed modulator assembly primary accumulator circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1400
Fig. 245 Primary Accumulator Circuit Bleed Screw Location
a. Connect clear bleed tube to primary accumulator circuit bleed screw, then place other end of
tube in a clear glass container partially filled with
clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using
DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit Valves." Right front and
left rear solenoids will fire
alternately for approximately five seconds.
d. Loosen primary accumulator circuit bleed screw one full turn. e. Continue bleeding primary
accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal
bottoms. f.
If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure.
g. Tighten primary accumulator bleed screw, then release brake pedal. Do not release pedal until
bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant
heavy force while opening primary accumulator circuit bleed screw one
full turn.
i. Without using DRB or allowing modulator solenoids to fire, bleed primary accumulator circuit until
brake fluid flowing through tube appears bubble-free and clean.
j. When brake fluid appears as specified, torque primary accumulator bleed screw to 80 in. lbs. and
release brake pedal. Do not release brake pedal until bleed screw is tight.
7. Bleed modulator assembly secondary sump circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1401
Fig. 246 Secondary Sump Circuit Bleed Screw Location
a. Connect clear bleed tube to secondary sump circuit bleed screw, then place other end of tube in
a clear glass container partially filled with
clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening secondary sump circuit bleed screw one
full turn.
c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves."
Left front and right rear solenoids will fire
alternately for approximately five seconds.
d. Continue to select "Secondary Circuit Valves" on DRB until brake fluid flowing through bleed
tube is bubble-free or until brake pedal
bottoms.
e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f.
Torque secondary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed
tube from screw. Do not release pedal until bleed screw is tight.
8. Bleed modulator assembly secondary accumulator circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1402
Fig. 247 Secondary Accumulator Circuit Bleed Screw Location
a. Connect clear bleed tube to secondary accumulator circuit bleed screw, then place other end of
tube in a clear glass container partially filled
with clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using
DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front
and right rear solenoids will fire
alternately for approximately five seconds.
d. Loosen secondary accumulator circuit bleed screw one full turn. e. Continue bleeding secondary
accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal
bottoms. f.
If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure.
g. Tighten secondary accumulator bleed screw, then release brake pedal. Do not release pedal
until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant
heavy force while opening secondary accumulator circuit bleed screw
one full turn.
i. Without using DRB or allowing modulator solenoids to fire, bleed secondary accumulator circuit
until brake fluid flowing through tube appears bubble-free and clean.
j. When brake fluid appears as specified, torque secondary accumulator bleed screw to 80 in. lbs.
and release brake pedal. Do not release brake pedal until bleed screw is tight.
9. Remove bleed tube and container, then install battery acid shield, tray support bracket, tray and
battery.
Pressure Bleeding
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1403
Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure)
When bleeding ABS systems use only diaphragm type bleed pressure bleeder.
1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a
minimum of 40 times to de-pressurize hydraulic
accumulator.
2. On all models, 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, then 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
DISARMING
1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at
least ten minutes after disconnecting battery ground cable before performing any further repairs on
vehicle. The SRS system is
designed to retain enough voltage to deploy air bag for a short time even after battery has been
disconnected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming > Page 1408
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
ARMING
1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side
of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one
is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning
light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate
SRS system is functioning correctly.
5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air
Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center
Fuse: Locations Power Distribution Center
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1414
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1415
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1416
Fuse: Locations Fuse Block Module
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1417
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1420
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1421
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1422
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1423
Fuse: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1424
Fuse: Electrical Diagrams
Fuse Application Chart (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1425
Fuse Application Chart (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1426
Fuse Application Chart (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1427
Fuse Application Chart (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Page 1428
Fuse: Service Precautions
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left
Dash Area
Fuse Block: Customer Interest Fuse Block - Rattle in Lower Left Dash Area
NO.: 08-46-93 Rev. A
GROUP: Electrical
DATE: Dec. 17, 1993
SUBJECT: Fuse Block Mounting Tabs Cracked
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION
THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL
THEM.
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006).
SYMPTOM/CONDITION:
A rattle may be heard at the lower left area of the instrument panel. This condition can be caused
by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket.
DIAGNOSIS:
Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered,
perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to
20 In.Lbs. (2.3 N-m).
PARTS REQUIRED:
1 4773171 Bracket
1 4773172 Bracket
REPAIR PROCEDURE:
This bulletin involves installing revised fuse block mounting brackets.
1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering
column cover.
2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing.
3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left
Dash Area > Page 1437
4. Using the two screws that attached the original bracket to the fuse block, assemble the service
brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the
screws to 20 In.Lbs. (2.3 N-m).
6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to
20 In.Lbs. (2.3 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 08-90-90-92 0.3 Hrs.
FAILURE CODE: 11 - Broken or Cracked
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in
Lower Left Dash Area
Fuse Block: All Technical Service Bulletins Fuse Block - Rattle in Lower Left Dash Area
NO.: 08-46-93 Rev. A
GROUP: Electrical
DATE: Dec. 17, 1993
SUBJECT: Fuse Block Mounting Tabs Cracked
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION
THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL
THEM.
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006).
SYMPTOM/CONDITION:
A rattle may be heard at the lower left area of the instrument panel. This condition can be caused
by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket.
DIAGNOSIS:
Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered,
perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to
20 In.Lbs. (2.3 N-m).
PARTS REQUIRED:
1 4773171 Bracket
1 4773172 Bracket
REPAIR PROCEDURE:
This bulletin involves installing revised fuse block mounting brackets.
1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering
column cover.
2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing.
3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in
Lower Left Dash Area > Page 1443
4. Using the two screws that attached the original bracket to the fuse block, assemble the service
brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the
screws to 20 In.Lbs. (2.3 N-m).
6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to
20 In.Lbs. (2.3 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 08-90-90-92 0.3 Hrs.
FAILURE CODE: 11 - Broken or Cracked
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Technical Service Bulletins > Page 1444
Fuse Block: Locations
Fuse panel is located below left side of instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1447
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1448
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1449
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1450
Fuse Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1451
Fuse Block: Electrical Diagrams
Fuse Application Chart (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1452
Fuse Application Chart (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1453
Fuse Application Chart (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1454
Fuse Application Chart (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1455
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1456
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1457
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1458
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1459
Fuse Block: Mechanical Diagrams
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1460
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1461
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1462
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1463
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Service
and Repair
Fusible Link: Service and Repair
Purpose
Fusible links protect vehicle electrical systems from damage due to excessive current.
^ The most common cause of excessive current is a short to ground caused by a component or
wiring failure.
Fusible links are color coded to indicate wire gauge and size.
Fig. 9 Fusible Link Chart
CAUTION:
Replace blown fusible links with correct gauge, hypalon insulated, fusible type wire ONLY.
^ Use of standard wire may result in severe damage to the electrical system or an electrical fire.
NOTE: Refer to the fusible link chart and the wiring diagrams for proper color and gauge
identification.
Replacement
Splicing Wires
CAUTION: If a fusible link has blown, find the cause before attempting to replace the link.
NOTE: If a faulty fusible link is suspected, it is important to carefully check the link for continuity
over its entire length. In some instances the link may look fine and actually be blown.
1. Disconnect battery negative cable.
2. Cut out the blown portion of the fusible link.
3. Strip 1 inch of insulation from each end of the existing fusible link.
4. Place a piece of heat shrink tubing long enough to cover and seal the entire repair area over one
side of the fusible link.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Service
and Repair > Page 1467
5. Cut a replacement piece of fusible link approximately two inches longer than the piece removed.
6. Remove one inch of insulation from each end of the replacement fusible link.
7. Spread the stripped ends of the wires apart (example 1).
8. Push the stripped ends of the wires together until the cut ends almost touch the insulation of the
other wire (example 2).
9. Twist the wires together (example 3).
10. Solder the wires together using rosin core type solder only. Never use acid core type solder for
soldering electrical/electronic connections.
11. Center the heat shrink tubing over the joint. Heat the joint with a heat gun until the tubing is
tightly sealed and sealant is coming out of both ends of the tubing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Locations > Power Distribution Center Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Locations > Power Distribution Center Location > Page 1472
Micro Relay Block: Locations Power Distribution Center Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Locations > Power Distribution Center Location > Page 1473
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Locations > Power Distribution Center Location > Page 1474
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Locations > Power Distribution Center Location > Page 1475
Micro Relay Block: Locations Micro Relay Block and Relay Bank Location
Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of
instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions
Micro Relay Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1478
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1479
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1480
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1481
Micro Relay Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1482
Micro Relay Block: Connector Views
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1483
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1484
Micro Relay Block: Electrical Diagrams
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1485
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1486
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component
Information > Diagrams > Diagram Information and Instructions > Page 1487
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Service Reminder Indicator Light <-->
[Emissions Maintenance Light] > Component Information > Description and Operation
Service Reminder Indicator Light: Description and Operation
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 Emission Maintenance Reminder (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. After necessary emission maintenance has been performed, connect Diagnosis
Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by
DRB II tool.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Locations
Malfunction Indicator Lamp: Locations
NOTE: MIL previously called Check Engine Lamp (CEL).
Light in instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Locations > Page 1495
Malfunction Indicator Lamp: Description and Operation
NOTE: Malfunction Indicator Lamp (MIL), previously called Check Engine Lamp (CEL). PURPOSE
Indicates immediate service of engine control system is required.
Informs driver that he has entered "Limp-In" mode, lamp ON while vehicle is being driven.
Displays Diagnostic Trouble Codes (DTC's), stored in memory.
OPERATION
Illuminates for three seconds when ignition switch is turned ON, (for bulb test).
Illuminates if Powertrain Control Module (PCM) receives an out of range input from a monitored
circuit, or, (for vehicles with California emissions), from an emission related device.
- Signals that can set Malfunction Indicator Lamp are battery voltage input, charging system,
Manifold Absolute Pressure (MAP), sensor, Throttle Position Sensor (TPS), Engine Coolant
Temperature (ECT) sensor.
Can be used to display any DTC's stored in memory, SEE POWERTRAIN
MANAGEMENT/COMPUTERS AND CONTROL SYSTEMS/TESTING AND INSPECTION.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Locations
Fig. 1 Caravan, Town & Country & Voyager
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1511
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1512
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1513
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1514
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1515
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1516
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1517
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1518
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1524
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1525
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1526
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1527
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1528
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1529
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1530
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1531
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout
Tires: All Technical Service Bulletins Tire & Wheel - Runout
NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT: Tire & Wheel Runout
MODELS: 1994 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge
measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the
tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the
following specifications and appropriate Service Manual procedures.
PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating
the tire on the wheel (match mounting).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake
NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994
SUBJECT: Smooth Road Vibration/Shake
MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A smooth road vibration/shake condition may be observed on smooth roads as:
- Low speed lateral wobble of the body (0-30 MPH)
- Steering wheel/seat/floor pan vibration at high speeds (60+ MPH)
Use the following flow chart for diagnosis and correction:
DYNAMIC CHECK
Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and
magnitude of vibration/shake condition.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1540
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1541
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1542
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1543
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1544
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout
Tires: All Technical Service Bulletins Tire & Wheel - Runout
NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT: Tire & Wheel Runout
MODELS: 1994 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge
measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the
tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the
following specifications and appropriate Service Manual procedures.
PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating
the tire on the wheel (match mounting).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake
NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994
SUBJECT: Smooth Road Vibration/Shake
MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A smooth road vibration/shake condition may be observed on smooth roads as:
- Low speed lateral wobble of the body (0-30 MPH)
- Steering wheel/seat/floor pan vibration at high speeds (60+ MPH)
Use the following flow chart for diagnosis and correction:
DYNAMIC CHECK
Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and
magnitude of vibration/shake condition.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1554
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1555
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1556
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1557
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1558
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels
Wheels: Recalls Recall - Stamped Steel Road Wheels
No. 603
January, 1994
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Safety Recall # 603 -- Stamped Steel Road Wheels
Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town
and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel
Wheels and/or a 15" Full Size Stamped Steel Spare.
The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut
torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing
plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this
recall.
IMPORTANT:
Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete
this recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the
same street address) will receive a copy of this dealer recall notification letter and a list of the
involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible
dealership personnel should be instructed to sign for this Certified Mail without hesitation as it
concerns urgent safety recall information.
The Vehicle List is 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.
All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall
notification letter by Compak mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall
implementation for dealer inquiry by VIN as needed.
Parts
Important:
Due to the small number of involved vehicles and the unknown number of wheels required for each
vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to
support scheduled repairs.
Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer
demand. Owners were requested to inspect their vehicle to determine the number of replacement
wheels required. Dealers should inquire if the owner performed the inspection and order the
required parts when scheduling the service appointment.
Each parts package contains the components (see illustration).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1567
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 inspect wheels for the suspect manufacturing plant code and/or
schedule appointments for the service with their dealers at the earliest possible date. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Service Procedure
A. Inspect Wheel Manufacturing Plant Code:
NOTE:
Vehicle may have one, four or five wheels to be inspected.
A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF):
a. Remove all wheel covers.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB):
a. Gain access to spare.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1568
A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected
wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel
covers and/or secure spare, no further action is required.
NOTE:
Replace only those wheels having the M1 plant code.
B. Replace Wheel:
B1. Remove all wheels with suspect M1 plant code. Discard lug nuts.
B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center.
B3. Install supplied valve stem(s).
B4. Mount and balance tire(s) on supplied wheel(s).
B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs.
(130 N-m) torque.
B6. Reinstall wheel cover(s) and/or secure spare.
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 labor operation numbers and time allowances (see illustration).
Add the cost of any recall parts packages used plus applicable dealer allowance to your claim.
Parts Return
Removed wheels must be returned to the Warranty Material Return Center.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim
processing and material return instructions.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1569
SAFETY RECALL -- Stamped Steel Road Wheels
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in
some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager
vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel
becoming loose. This could result in an accident without prior warning.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange
for service to correct the condition without delay. The service and required parts as described in
this letter will be provided free of charge.
The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper,
which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with
15" wheels with full wheel covers and also for 15" full size spare tires.
You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of
this letter for details. If no suspect wheels are found, no further action is necessary. Please mark
"INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner
notification form and put it in the mail. No postage is required. If you prefer not to do the inspection
yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect
the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection
will take less than one-half hour to complete. However, additional time may be required depending
on how many wheels require replacement and how dealer appointments are scheduled and
processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the service. If you
performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels
found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service
appointment.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it
to your dealer. The form identifies the vehicle and the service that is required.
If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll
free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired.
We regret any inconvenience which this action may cause you. However, we are concerned about
your safety. If your dealer fails or is unable to remedy this defect without charge and within a
reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free
Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.
STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN,
PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY
FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^
Remove all wheel covers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1570
^ Inspect wheel manufacturing plant code located above valve stem as shown.
^ Reinstall wheel covers.
FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain
access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing
plant code located above valve stem as shown.
If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment
with your dealer to have the suspect wheel(s) replaced.
NOTE:
Plant code may be covered by a green sticker. Remove and discard sticker as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1576
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1577
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1578
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1579
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1580
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1581
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1582
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1583
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1589
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1590
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1591
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1592
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1593
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1594
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1595
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1596
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout
Wheels: All Technical Service Bulletins Tire & Wheel - Runout
NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT: Tire & Wheel Runout
MODELS: 1994 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge
measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the
tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the
following specifications and appropriate Service Manual procedures.
PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating
the tire on the wheel (match mounting).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
Wheels: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake
NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994
SUBJECT: Smooth Road Vibration/Shake
MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A smooth road vibration/shake condition may be observed on smooth roads as:
- Low speed lateral wobble of the body (0-30 MPH)
- Steering wheel/seat/floor pan vibration at high speeds (60+ MPH)
Use the following flow chart for diagnosis and correction:
DYNAMIC CHECK
Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and
magnitude of vibration/shake condition.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
> Page 1605
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
> Page 1606
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
> Page 1607
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
> Page 1608
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
> Page 1609
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels
Wheels: All Technical Service Bulletins Recall - Stamped Steel Road Wheels
No. 603
January, 1994
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Safety Recall # 603 -- Stamped Steel Road Wheels
Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town
and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel
Wheels and/or a 15" Full Size Stamped Steel Spare.
The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut
torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing
plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this
recall.
IMPORTANT:
Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete
this recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the
same street address) will receive a copy of this dealer recall notification letter and a list of the
involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible
dealership personnel should be instructed to sign for this Certified Mail without hesitation as it
concerns urgent safety recall information.
The Vehicle List is 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.
All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall
notification letter by Compak mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall
implementation for dealer inquiry by VIN as needed.
Parts
Important:
Due to the small number of involved vehicles and the unknown number of wheels required for each
vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to
support scheduled repairs.
Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer
demand. Owners were requested to inspect their vehicle to determine the number of replacement
wheels required. Dealers should inquire if the owner performed the inspection and order the
required parts when scheduling the service appointment.
Each parts package contains the components (see illustration).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page
1614
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 inspect wheels for the suspect manufacturing plant code and/or
schedule appointments for the service with their dealers at the earliest possible date. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Service Procedure
A. Inspect Wheel Manufacturing Plant Code:
NOTE:
Vehicle may have one, four or five wheels to be inspected.
A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF):
a. Remove all wheel covers.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB):
a. Gain access to spare.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page
1615
A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected
wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel
covers and/or secure spare, no further action is required.
NOTE:
Replace only those wheels having the M1 plant code.
B. Replace Wheel:
B1. Remove all wheels with suspect M1 plant code. Discard lug nuts.
B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center.
B3. Install supplied valve stem(s).
B4. Mount and balance tire(s) on supplied wheel(s).
B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs.
(130 N-m) torque.
B6. Reinstall wheel cover(s) and/or secure spare.
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 labor operation numbers and time allowances (see illustration).
Add the cost of any recall parts packages used plus applicable dealer allowance to your claim.
Parts Return
Removed wheels must be returned to the Warranty Material Return Center.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim
processing and material return instructions.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page
1616
SAFETY RECALL -- Stamped Steel Road Wheels
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in
some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager
vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel
becoming loose. This could result in an accident without prior warning.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange
for service to correct the condition without delay. The service and required parts as described in
this letter will be provided free of charge.
The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper,
which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with
15" wheels with full wheel covers and also for 15" full size spare tires.
You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of
this letter for details. If no suspect wheels are found, no further action is necessary. Please mark
"INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner
notification form and put it in the mail. No postage is required. If you prefer not to do the inspection
yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect
the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection
will take less than one-half hour to complete. However, additional time may be required depending
on how many wheels require replacement and how dealer appointments are scheduled and
processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the service. If you
performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels
found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service
appointment.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it
to your dealer. The form identifies the vehicle and the service that is required.
If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll
free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired.
We regret any inconvenience which this action may cause you. However, we are concerned about
your safety. If your dealer fails or is unable to remedy this defect without charge and within a
reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free
Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.
STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN,
PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY
FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^
Remove all wheel covers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page
1617
^ Inspect wheel manufacturing plant code located above valve stem as shown.
^ Reinstall wheel covers.
FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain
access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing
plant code located above valve stem as shown.
If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment
with your dealer to have the suspect wheel(s) replaced.
NOTE:
Plant code may be covered by a green sticker. Remove and discard sticker as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1623
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1624
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1625
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1626
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1627
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1628
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1629
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1630
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout
Wheels: All Technical Service Bulletins Tire & Wheel - Runout
NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT: Tire & Wheel Runout
MODELS: 1994 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge
measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the
tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the
following specifications and appropriate Service Manual procedures.
PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating
the tire on the wheel (match mounting).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake
Wheels: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake
NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994
SUBJECT: Smooth Road Vibration/Shake
MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A smooth road vibration/shake condition may be observed on smooth roads as:
- Low speed lateral wobble of the body (0-30 MPH)
- Steering wheel/seat/floor pan vibration at high speeds (60+ MPH)
Use the following flow chart for diagnosis and correction:
DYNAMIC CHECK
Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and
magnitude of vibration/shake condition.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1639
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1640
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1641
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1642
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1643
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1653
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1654
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1655
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1656
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake >
Page 1657
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels
Wheels: All Technical Service Bulletins Recall - Stamped Steel Road Wheels
No. 603
January, 1994
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Safety Recall # 603 -- Stamped Steel Road Wheels
Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town
and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel
Wheels and/or a 15" Full Size Stamped Steel Spare.
The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut
torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing
plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this
recall.
IMPORTANT:
Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete
this recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the
same street address) will receive a copy of this dealer recall notification letter and a list of the
involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible
dealership personnel should be instructed to sign for this Certified Mail without hesitation as it
concerns urgent safety recall information.
The Vehicle List is 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.
All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall
notification letter by Compak mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall
implementation for dealer inquiry by VIN as needed.
Parts
Important:
Due to the small number of involved vehicles and the unknown number of wheels required for each
vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to
support scheduled repairs.
Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer
demand. Owners were requested to inspect their vehicle to determine the number of replacement
wheels required. Dealers should inquire if the owner performed the inspection and order the
required parts when scheduling the service appointment.
Each parts package contains the components (see illustration).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1662
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 inspect wheels for the suspect manufacturing plant code and/or
schedule appointments for the service with their dealers at the earliest possible date. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Service Procedure
A. Inspect Wheel Manufacturing Plant Code:
NOTE:
Vehicle may have one, four or five wheels to be inspected.
A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF):
a. Remove all wheel covers.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB):
a. Gain access to spare.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1663
A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected
wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel
covers and/or secure spare, no further action is required.
NOTE:
Replace only those wheels having the M1 plant code.
B. Replace Wheel:
B1. Remove all wheels with suspect M1 plant code. Discard lug nuts.
B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center.
B3. Install supplied valve stem(s).
B4. Mount and balance tire(s) on supplied wheel(s).
B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs.
(130 N-m) torque.
B6. Reinstall wheel cover(s) and/or secure spare.
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 labor operation numbers and time allowances (see illustration).
Add the cost of any recall parts packages used plus applicable dealer allowance to your claim.
Parts Return
Removed wheels must be returned to the Warranty Material Return Center.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim
processing and material return instructions.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1664
SAFETY RECALL -- Stamped Steel Road Wheels
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in
some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager
vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel
becoming loose. This could result in an accident without prior warning.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange
for service to correct the condition without delay. The service and required parts as described in
this letter will be provided free of charge.
The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper,
which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with
15" wheels with full wheel covers and also for 15" full size spare tires.
You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of
this letter for details. If no suspect wheels are found, no further action is necessary. Please mark
"INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner
notification form and put it in the mail. No postage is required. If you prefer not to do the inspection
yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect
the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection
will take less than one-half hour to complete. However, additional time may be required depending
on how many wheels require replacement and how dealer appointments are scheduled and
processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the service. If you
performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels
found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service
appointment.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it
to your dealer. The form identifies the vehicle and the service that is required.
If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll
free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired.
We regret any inconvenience which this action may cause you. However, we are concerned about
your safety. If your dealer fails or is unable to remedy this defect without charge and within a
reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free
Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.
STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN,
PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY
FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^
Remove all wheel covers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1665
^ Inspect wheel manufacturing plant code located above valve stem as shown.
^ Reinstall wheel covers.
FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain
access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing
plant code located above valve stem as shown.
If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment
with your dealer to have the suspect wheel(s) replaced.
NOTE:
Plant code may be covered by a green sticker. Remove and discard sticker as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel.
3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay
should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter
pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front
Wheel Bearing: Service and Repair Front
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1671
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1672
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1673
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1674
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1675
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1676
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1677
Wheel Bearing: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front
Wheel Hub: Service and Repair Front
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front > Page 1682
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front > Page 1683
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front > Page 1684
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front > Page 1685
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front > Page 1686
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front > Page 1687
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Front > Page 1688
Wheel Hub: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Recalls for Wheel Fastener: > NHTSA93V215000 > Dec > 93 > Recall 93V215000: Defective Wheel Lug
Nut Seats
Wheel Fastener: Recalls Recall 93V215000: Defective Wheel Lug Nut Seats
WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES.
THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL
SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL
LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO
WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT.
INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE
PROBLEM AND INSTALL NEW LUG NUTS.
SYSTEM: WHEELS; LUGS; NUTS.
VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15"
STAMPED STEEL SPARE WHEEL.
NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT
THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE
ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE
FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY
TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN
1994 PLYMOUTH TRUCK GRAND VOYAGER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA93V215000 > Dec > 93 > Recall
93V215000: Defective Wheel Lug Nut Seats
Wheel Fastener: All Technical Service Bulletins Recall 93V215000: Defective Wheel Lug Nut Seats
WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES.
THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL
SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL
LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO
WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT.
INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE
PROBLEM AND INSTALL NEW LUG NUTS.
SYSTEM: WHEELS; LUGS; NUTS.
VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15"
STAMPED STEEL SPARE WHEEL.
NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT
THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE
ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE
FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY
TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN
1994 PLYMOUTH TRUCK GRAND VOYAGER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Page 1702
Wheel Fastener: Specifications
Fig 6 Wheel Stud Tightening Sequence
When tightening wheel stud nuts, a criss-cross tightening sequence as shown should be followed.
Tighten all stud nuts to one-half specified torque. Repeat, fully tightening to specified torque.
Wheel stud lug nut torque 129 Nm (95 ft lb)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Locations
Fig. 1 Caravan, Town & Country & Voyager
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Cylinder Compression Pressure 100 psi
NOTE: No more than 25% variance between cylinders.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1711
Compression Check: Service Precautions
COMPRESSION TESTING
When performing a compression test, remove the fuel pump relay fuse and disconnect power to
the ignition. This will stop fuel flow to the injectors and prevent engine from starting.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1712
Compression Check: Testing and Inspection
PROCEDURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. 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. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For
Direct Ignition System (DIS) disconnect the coil connector.
5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage.
Record this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689
kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem
in the cylinder in question. The recommended compression pressures are to be used only as a
guide to diagnosing engine problems. An engine should not be disassembled to determine the
cause of low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16.
Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test
vehicle as a final test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Specifications
Camshaft Bearing: Specifications
DIAMETER:
No. 1
..............................................................................................................................................................
50.825 - 50.800 mm (2.0009 - 1.9999 inch) No. 2
..............................................................................................................................................................
50.419 - 50.393 mm (1.9849 - 1.9839 inch) No. 3
..............................................................................................................................................................
50.038 - 50.013 mm (1.9699 - 1.9690 inch) No. 4
..............................................................................................................................................................
49.632 - 49.606 mm (1.9540 - 1.9529 inch)
Oil Clearance
.........................................................................................................................................................
0.0254 - 0.0762 mm (0.001 - 0.003 inch)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Specifications > Page 1717
Camshaft Bearing: Service and Repair
REMOVAL
1. With engine removed from vehicle and completely disassembled, drive out rear cam bearing
core hole plug. 2. Install proper size adapters and horseshoe washers part of Tool C-3132-A, or
equivalent at back of each bearing shell to be removed and drive out
bearing shells.
INSTALLATION
1. Install new camshaft bearings with Tool C-3132-A, or equivalent by sliding the new camshaft
bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horse-shoe lock and
by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining
bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register
with oil passages from the
main bearing. Number two bearing must index with the oil passage to the left cylinder head and
Number three bearing must index with the oil passage to the right cylinder head. If the camshaft
bearing shell oil holes are not in exact alignment, remove and reinstall them correctly. Install a new
core hole plug at the rear of camshaft. Be sure this plug does not leak.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Specifications > Page 1718
Camshaft Bearing Remover and Installer C-3132-A
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
.................................................... 54 Nm (40 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust
Plate > Component Information > Specifications
Camshaft Thrust Plate: Specifications
Mounting Bolts .....................................................................................................................................
............................................... 12 Nm (105 inch lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications
Camshaft: Specifications
CAMSHAFT
Drive ....................................................................................................................................................
.................................................................... Chain Bearings ...............................................................
............................................................................................................................ Steel Backed
Babbitt Number ....................................................................................................................................
....................................................................................... 4 Diametral Clearance
................................................................................................................................................ 0.025 0.101 mm (0.001 - 0.004 in.)
Maximum Allowable Before Reconditioning
............................................................................................................................ 0.127 mm (0.005
in.)
Thrust Taken By ..................................................................................................................................
.......................................................... Thrust Plate End Play ...............................................................
................................................................................................... 0.127 - 0.304 mm (0.005 - 0.012 in.)
Maximum Allowable .............................................................................................................................
.......................................... 0.304 mm (0.012 in.)
CAMSHAFT JOURNALS
Diameter
No. 1
.........................................................................................................................................................
50.724 - 50.775 mm (1.9970 - 1.9990 in.) No. 2
.........................................................................................................................................................
50.317 - 50.368 mm (1.9809 - 1.9829 in.) No. 3
.........................................................................................................................................................
49.936 - 49.987 mm (1.9659 - 1.9679 in.) No. 4
.........................................................................................................................................................
49.530 - 49.581 mm (1.9499 - 1.9520 in.)
CAMSHAFT BEARINGS
Diameter
No. 1
.........................................................................................................................................................
50.825 - 50.800 mm (2.0009 - 1.9999 in.) No. 2
.........................................................................................................................................................
50.419 - 50.393 mm (1.9849 - 1.9839 in.) No. 3
.........................................................................................................................................................
50.038 - 50.013 mm (1.9699 - 1.9690 in.) No. 4
.........................................................................................................................................................
49.632 - 49.606 mm (1.9540 - 1.9529 in.) Oil Clearance
.........................................................................................................................................................
.0254 - .0762 mm (.001 - 003 in.)
VALVE TIMING
Intake Opens (BTC) .............................................................................................................................
......................................................................... 2° Intake Closes (ABC) .............................................
....................................................................................................................................................... 58°
Exhaust Opens (BBC) .........................................................................................................................
........................................................................ 48° Exhaust Closes (ATC) .........................................
........................................................................................................................................................
12° Valve Overlap ...............................................................................................................................
............................................................................... 14° Intake Valve Duration ....................................
...........................................................................................................................................................
240° Exhaust Valve Duration ..............................................................................................................
............................................................................... 240°
TIMING CHAIN
Number of Links ..................................................................................................................................
......................................................................... 64 Pitch ......................................................................
.............................................................................................................................................. 0.375 in.
Width ...................................................................................................................................................
............................................................... 0.750 in.
TAPPETS
Type .....................................................................................................................................................
................................................... Roller Hydraulic Body Diameter
.................................................................................................................................................... 22.95
- 22.96 mm (0.9035 - 0.9040 in.) Clearance to Block
.................................................................................................................................................. 0.02 0.06 mm (0.0007 - 0.0024 in.) Service Tappets Available ...................................................................
....................................................................................................................... Std.
..............................................................................................................................................................
...................................... 0.025 mm (0.001 in.) ....................................................................................
.................................................................................................................. 0.20 mm (0.008 in.) ..........
..............................................................................................................................................................
............................ 0.762 mm (0.030 in.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications > Page 1728
Camshaft: Description and Operation
The nodular iron camshaft is mounted in four steel backed Babbitt bearings. A thrust plate located
in front of the first bearing, and bolted to the block, controls end play. Silent timing chain drives the
camshaft. This chain is enclosed by a cast aluminum cover which also carries a front crankshaft
seal, provides front oil pan closure and water pump mounting.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Camshaft Replacement
Camshaft: Service and Repair Camshaft Replacement
1. Remove intake manifold as described under Intake Manifold Replacement. 2. Remove timing
case cover and chain as described under Timing Chain Service. 3. Remove rocker arm and shaft
assemblies and cylinder heads as described under Cylinder Head Replacement. 4. Remove
camshaft thrust plate. 5. Install a long bolt into camshaft to facilitate removal of camshaft, then
remove camshaft. 6. Reverse procedure to install, noting following:
a. Tighten thrust plate to specifications. b. Refer to Timing Chain Service for installation of timing
chain and sprockets. c. If new camshaft is installed, new tappets must be used.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1731
Camshaft: Service and Repair Removal and Installation
Replacement With Engine Out of Vehicle
REMOVAL
Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover and timing
chain. 1. Remove rocker arm and shaft assemblies. 2. Remove push rods and tappets; identify so
each part will be replaced in its original location.
3. Remove camshaft thrust plate. 4. Install a long bolt into front of camshaft to facilitate removal of
the camshaft; remove camshaft, being careful not to damage cam bearings with
the cam lobes.
INSTALLATION
1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2
inches of its final position in cylinder block.
NOTE: Whenever an engine has been rebuilt or a new camshaft or tappets have been installed,
add one pint of Mopar (R) Engine Oil Supplement or equivalent to engine oil to aid in break-in. The
oil mixture should be left in engine for a minimum of 805 km (500 miles) and drained at the next
normal oil change.
2. Install camshaft thrust plate with two screws as shown. Tighten to 12 Nm (105 inch lbs.) torque.
3. Rotate crankshaft so the timing arrow is at the 12 o'clock position. 4. Place timing chain around
camshaft sprocket and place the timing mark to the 6 o'clock position. 5. Align the dark colored
links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the
dark colored link lined
up with the dot on the sprocket and install camshaft sprocket into position.
6. Using straight edge to check alignment of timing marks. 7. Install the camshaft bolt. Tighten bolt
to 54 Nm (40 ft. lbs.). 8. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing
marks do not line up, remove cam sprocket and realign. 9. Measure camshaft end play. End Play
should measure 0.0127 to 0.304 mm (0.005 to 0.012 inch) 0.310 mm (0.012 inch Max.). If not
within
limits install a new thrust plate.
10. Each tappet reused must be installed in the same position from which it was removed. When
camshaft is replaced, all of the tappets must be
replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash
Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications
Hydraulic Lash Adjuster: Specifications
Type .....................................................................................................................................................
........................................................ Roller Hydraulic Body Diameter
......................................................................................................................................................
22.95 - 22.96 mm (0.9035 - 0.9040 inch) Clearance To Block
................................................................................................................................................... 0.02 0.06 mm (0.0007 - 0.0024 inch) Retainer Yoke Screw ........................................................................
................................................................................................... 12 Nm (105 inch lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash
Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications > Page 1735
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash
Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications > Page 1736
Hydraulic Lash Adjuster: Testing and Inspection
GENERAL INFORMATION
The valve train includes roller tappet assemblies, aligning yokes and yoke retainer. Roller tappet
alignment is maintained by machined flats on tappet body being fitted in pairs into six aligning
yokes. The yokes are secured by an alignment yoke retainer.
PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, read the oil pressure at the
gauge. Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and
check the of level in the oil pan. The pressure should be between 30 and 80 psi (206.8 to 651.6
kPa) at 2000 rpm. The oil level in the pan should never be above the MAX mark on dipstick, or
below the MIN mark. Either of these two conditions could be responsible for noisy tappets. Oil
Level Check: stop engine after reaching normal operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick.
Oil Level Too High If oil level is above the MAX mark on dip stick, it is possible for the connecting
rods to dip into the oil while engine is running and create foam. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to become soft and allow valves to seat noisily.
Oil Level Too Low Low oil level may allow pump to take in air which when fed to the tappets,
causes them to become soft and allows valves to seat noisily. Any leaks on intake side of pump
through which air can be drawn will create the same tappet action. Check the lubrication system
from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be
noisy. When oil level and leaks have been corrected, engine should be operated at fast idle to
allow all of the air inside of the tappets to be bled out.
VALVE TRAIN NOISE DIAGNOSIS
To determine if a clicking noise coming from the engine compartment is caused by a tappet.
Increase the engine speed above idle speed to check if the clicking frequency rises with engine
speed. If it does not, the clicking noise is not coming from the engine.
If it is determined that the clicking noise is coming from the engine, alternately increase and
decrease the engine speed quickly by opening and closing the throttle. If the clicking noise
changes significantly in loudness from when the engine speed is increasing te engine speed
decreasing, the noise is probably net coming from the tappet.
Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by
excessive leak-down around the unit plunger which will necessitate replacing the tappet, or by the
plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet
check valve nOt seating, or by foreign particles becoming wedged between the plunger and the
tappet body causing the plunger to stick in the down position. This heavy click will be accompanied
by excessive clearance between the valve stem and rocker arm as valve closes. In either case,
tappet assembly should be removed for inspection and clesning.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash
Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Service and Repair > Removal and Installation
Hydraulic Lash Adjuster: Service and Repair Removal and Installation
REMOVAL
1. Cylinder Head must be removed to gain access to tappets for service. 2. Remove yoke retainer
and aligning yokes. 3. Use Tool C-4129, or equivalent to remove tappets from their bores. If all
tappets are to be removed, identify tappets to insure installation in
original location.
NOTE: If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the
bore to next oversize and replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing
of parts. Mixed parts are not compatible. Do not disassemble a tappet on a dirty work bench.
INSTALLATION
1. Lubricate tappets. 2. Install tappets in their original positions. 3. With roller tappets, install
aligning yokes. 4. Install yoke retainer and torque screws to 12 Nm (105 inch lbs.). 5. Install
cylinder heads. 6. Start and operate engine. Warm up to normal operating temperature.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have become quiet.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash
Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Service and Repair > Removal and Installation >
Page 1739
Hydraulic Lash Adjuster: Service and Repair Disassembly and Assembly
DISASSEMBLY
1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above
plunger cap. 3. Invert tappet body and remove plunger cap, plunger, flat or ball check valve, check
valve spring, check valve retainer and plunger spring. Check
valve could be flat or ball.
ASSEMBLY
1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets
that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear,
valve is pitted, or valve seat on end of plunger indicates any condition that would prevent valve
from
seating, install a new tappet assembly.
4. Assemble tappets.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Rocker Arm and Shaft
Rocker Arm Assembly: Specifications Rocker Arm and Shaft
Bracket Bolt .........................................................................................................................................
............................................... 28 Nm (250 inch lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Rocker Arm and Shaft > Page 1744
Rocker Arm Assembly: Specifications
Rocker Arm Bolts 250 in.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1745
Rocker Arm Assembly: Description and Operation
Rocker arms are installed on a rocker arm shaft attached to the cylinder head with four bolts and
retainers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1746
Rocker Arm Assembly: Service and Repair
REMOVAL
1. Remove upper intake manifold assembly. Refer to Intake Manifold. 2. Disconnect spark plug
wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4.
Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6.
Remove rocker arms and shaft assembly. 7. If rocker arm assemblies are disassembled for
cleaning or replacement, re-assemble rocker arms in their original position.
INSTALLATION
1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions,
tighten to 28 Nm (250 in. lbs.).
CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts.
Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine
operation.
2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if
necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover
fasteners to 12 Nm (105 in. lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug
wires. 6. Install upper intake manifold assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Specifications
Connecting Rod Bearing: Specifications
CONNECTING RODS
Side Clearance
........................................................................................................................................................
0.127 - 0.381 mm (0.005 - 0.015 in.)
CONNECTING ROD BEARINGS
Type .....................................................................................................................................................
.................................. Aluminum Lead (Bi-Metal) Clearance Desired
............................................................................................................................................... 0.019 0.076 mm (0.00075 - 0.003 in.) Maximum Allowable (wear limit)
................................................................................................................................................... 0.102
mm (0.004 in.) Bearings for Service ....................................................................................................
................................................................................................ Std.
..............................................................................................................................................................
...................................... 0.025 mm (0.001 in.) ....................................................................................
................................................................................................................ 0.051 mm (0.002 in.) ..........
..............................................................................................................................................................
............................ 0.076 mm (0.003 in.) ..............................................................................................
...................................................................................................... 0.254 mm (0.010 in.) ....................
..............................................................................................................................................................
.................. 0.305 mm (0.012 in.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Service and Repair > Fitting Connecting Rod Bearings
Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings
GENERAL INFORMATION
Fit all rods on one bank until complete. The bearing caps are not interchangeable and should be
marked at removal to insure correct assembly. The bearing shells must be installed with the tangs
inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same
side as the rod.
SIZES
Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) undersize. Install the bearings in pairs. Do not
use a new bearing half with an old bearing half. Do not file the rods or bearing caps.
PROCEDURE
1. Measure Main Bearing Clearance and Connecting Rod Bearing Clearance.
NOTE: The rod bearing bolts should be examined before reuse. If the threads are necked down the
bolts should be replaced. Necking can be checked by holding a scale or straight edge against the
threads. If all the threads do not contact the scale the bolt should be replaced.
2. Before installing the nuts the threads should be oiled with engine oil. 3. Install nuts finger tight on
each bolt then alternately torque each nut to assemble the cap properly. 4. Tighten the nuts to 54
Nm PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1753
5. Using a feeler gauge, check connecting rod side clearance. Refer to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1754
Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Clearance
Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent.
The following is the recommended procedure for the use of Plastigage:
1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. 2.
Remove oil film from surface to be checked. Plastigage is soluble in oil.
3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap
approximately 6.35 mm (1/4 inch) off center and away
from the oil hole. In addition, suspect areas can be checked by placing plastigage in the suspect
area.
4. Before assembling the rod cap with Plastigage in place, the crankshaft must be rotated until the
connecting being checked starts moving toward the
top of the engine. Only then should the cap be assembled and torqued to specifications. Do not
rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving
inaccurate results.
5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale
provided on the package. Locate the band closest to the
same width. This band indicates the amount of oil clearance. Differences in readings between the
ends indicate the amount of taper present. Record all readings taken. Refer to Engine
Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle
Connecting Rod: Technical Service Bulletins Engine - Piston Knock at Idle
NO: 09-03-94 GROUP: Engine DATE: Apr. 1, 1994
SUBJECT: Engine Idle Piston Noise
MODELS: 1990 - 1993
(AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1994 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1994 (LH) Concorde/intrepid/Vision
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 3.3L AND 3.8L ENGINE
SYMPTOM/CONDITION:
Cold start up piston knocking noise at idle that diminishes 3 to 5 minutes after start up. The
condition is more prominent in low ambient temperatures and after the vehicle has set overnight.
Similar symptoms are described in Technical Service Bulletin 09-21-93 dated Dec. 31, 1993,
"Carbon Buildup on Top of Piston". Refer to this Bulletin for additional details.
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 are present and all systems are functioning correctly, and carbon buildup on
the top of the piston is not evident, proceed with the following repair.
PARTS REQUIRED:
AR 4621978 Piston & Connecting Rod Assy. (use w/3.3L engine)
AR 4621981 Piston & Connecting Rod Assy. (use w/3.8L engine)
REPAIR PROCEDURE:
This repair involves installing a new coated piston and connecting rod assembly.
1. Following the procedure outlined in the appropriate Service Manual, remove the engine piston
and connecting rods.
2. Install the new coated piston and connecting rod assembly as outlined in the Service Manual.
NOTE:
HONING OF THE CYLINDER BORES IS NOT RECOMMENDED.
DISCUSSION:
The new pistons have a coating bonded only to the piston skirt that is black in appearance. This
new coating replaces the previously used tin coating.
Items of special interest include:
1. The new coated pistons are available in one size only and are serviced with the piston pin and
connecting rod as an assembly.
2. The new coated piston connecting rod assembly can be used to service all models listed and
can be replaced one at a time (complete engine sets are not required).
3. Tin coated pistons should not be used as replacements for the coated pistons.
4. The coating material is applied after the final piston machining process. Therefore, the step for
measuring the outside diameter of the piston to determine size or piston to bore clearance is not
required.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle > Page 1759
5. Measuring the inside diameter of the cylinder bore with a Bore Gauge is still required. Dial
Cylinder Bore Indicator, Tool C-119 available from Miller Special Tools, is recommended. Follow
the procedure outlined in the Service Manual.
If the cylinder bore measures larger than 3.664 inches (93.059 mm) for the 3.3L Engine, or 3.782
inches (96.059 mm) for the 3.8L Engine, the cylinder block will require replacement.
6. Piston installation into the cylinder bore may require slightly more pressure than that required for
non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit
with the cylinder bore.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
1990 - 1994 AC, AS, AY (W/3.3L or 3.8L Engine) Piston and Connecting Rod Replace
Labor Operation No.
09-70-01-91 One - Front Bank 4.2 Hrs.
09-70-01-92 One - Rear Bank 4.5 Hrs.
09-70-01-93 One - Each Bank 6.0 Hrs.
09-70-01-94 Each Additional 0.5 Hrs.
09-70-01-63 A/C Equipped 0.2 Hrs.
09-70-01-64 Power Steering Equipped (AS Only) 0.2 Hrs.
1993 - 1994 LH (w/3.3L or 3.8L Engine) Piston and Connecting Rod Replace
Labor Operation No.
09-70-01-95 One - Left Bank 4.1 Hrs.
09-70-01-96 One - Right Bank 3.7 Hrs.
09-70-01-97 One - Each Bank 5.2 Hrs.
09-70-01-98 Each Additional 0.5 Hrs.
09-70-01-63 A/C Equipped 0.3 Hrs.
FAILURE CODE: 58 - Noisy Cold Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Specifications
Connecting Rod: Specifications Connecting Rod Specifications
CONNECTING RODS
Side Clearance
........................................................................................................................................................
0.127 - 0.381 mm (0.005 - 0.015 in.)
CONNECTING ROD BEARINGS
Type .....................................................................................................................................................
.................................. Aluminum Lead (Bi-Metal) Clearance Desired
............................................................................................................................................... 0.019 0.076 mm (0.00075 - 0.003 in.) Maximum Allowable (wear limit)
................................................................................................................................................... 0.102
mm (0.004 in.) Bearings for Service ....................................................................................................
................................................................................................ Std.
..............................................................................................................................................................
...................................... 0.025 mm (0.001 in.) ....................................................................................
................................................................................................................ 0.051 mm (0.002 in.) ..........
..............................................................................................................................................................
............................ 0.076 mm (0.003 in.) ..............................................................................................
...................................................................................................... 0.254 mm (0.010 in.) ....................
..............................................................................................................................................................
.................. 0.305 mm (0.012 in.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Service and Repair > Removal and Installation
Connecting Rod: Service and Repair Removal and Installation
NOTE: Heads and Oil Pan have to be removed first.
REMOVAL
1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from
cylinder block. Be sure to keep tops of pistons
covered during this operation. Pistons and connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod assemblies from the engine; rotate crankshaft so
that each connecting rod is centered in cylinder bore.
2. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if
necessary.
3. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push
each piston and rod assembly out of cylinder
bore.
NOTE: Be careful not to nick crankshaft journals.
4. After removal, install bearing cap on the mating rod.
INSTALLATION
1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Service and Repair > Removal and Installation > Page 1764
with oil ring rail gap.
2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the
rail gaps located as shown. 3. Immerse the piston head and rings in clean engine oil, slide the ring
compressor, over the piston and tighten with the special wrench. Be sure
position of rings does not change during this operation.
4. Install connecting rod bolt protectors on rod bolts.
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod
over the crankshaft journal.
6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide
connecting rod into position on connecting rod journal.
7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps.
Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lb.) Plus 1/4 turn.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Service and Repair > Removal and Installation > Page 1765
Connecting Rod: Service and Repair Disassembly and Assembly
Fig. 22 Piston Measurements
Fig. 23 Piston Ring Installation
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Service and Repair > Removal and Installation > Page 1766
Fig. 24 Piston Ring Installation
Fig. 25 Ring End Gap Orientation
When installing piston and rod assemblies notch in piston top must point toward front of engine.
Refer to Fig. 22 through 25 for piston measurements and ring installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Sprocket <-->
[Crankshaft Gear/Sprocket] > Component Information > Description and Operation
Crankshaft Sprocket: Description and Operation
ACCESS PLUG
An Access plug is located in the right inner fender shield. Remove the plug and insert the proper
size socket, extension and ratchet, when crankshaft rotation is necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Specifications
Crankshaft Main Bearing: Specifications
CRANKSHAFT
Type .....................................................................................................................................................
................................................. Cast Nodular Iron Bearings ...............................................................
................................................................................................................ Aluminum Lead (Bi - Metal)
Thrust Taken By ..................................................................................................................................
.............................................. No. 2 Main Bearing End Play ...............................................................
................................................................................................... 0.076 - 0.228 mm (0.003 - 0.009 in.)
Maximum Allowable (wear limit)
................................................................................................................................................... 0.381
mm (0.015 in.) Diametral Clearance Desired
................................................................................................................................ 0.018 - 0.076 mm
(0.0007 - 0.003 in.) Maximum Diametral Clearance (wear limit)
................................................................................................................................... 0.102 mm
(0.004 in.)
MAIN BEARING JOURNALS
Diameter ..............................................................................................................................................
................................................. 64 mm (2.519 in.) Maximum Out-of-Round and/or Taper
............................................................................................................................................ 0.025 mm
(0.001 in.) Bearings for Service ...........................................................................................................
......................................................................................... Std.
..............................................................................................................................................................
...................................... 0.025 mm (0.001 in.) ....................................................................................
................................................................................................................ 0.051 mm (0.002 in.) ..........
..............................................................................................................................................................
............................ 0.076 mm (0.003 in.) ..............................................................................................
...................................................................................................... 0.254 mm (0.010 in.) ....................
..............................................................................................................................................................
.................. 0.305 mm (0.012 in.)
CONNECTING ROD JOURNALS
Diameter ..............................................................................................................................................
................................................. 58 mm (2.283 in.) Maximum Out-of-Round and/or Taper
............................................................................................................................................ 0.025 mm
(0.001 in.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Removal and Installation
Crankshaft Main Bearing: Service and Repair Removal and Installation
REMOVAL
1. Remove oil pan and identify bearing caps before removal. 2. Remove bearing caps one at a
time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059 into the oil hole
of crankshaft. 3. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.
NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are
properly tightened.
INSTALLATION
When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1.
Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft. 2. Slowly
rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing
Tool C-3059. 3. Install each main cap and tighten bolts finger tight. 4. Tighten number 1, 3 and 4
main cap bolts to 41 Nm plus a 1/4 Turn (30 ft. lbs.) plus a 1/4 Turn. 5. Rotate the crankshaft until
number 6 piston is at Top Dead Center (TDC). 6. To ensure correct thrust bearing alignment the
following procedure must be done:
a. Move crankshaft all the way to the rear of its travel. b. Then, move crankshaft all the way to the
front of its travel. c. Wedge a appropriate tool between. the rear of the cylinder block and rear
crankshaft counterweight. This will hold the crankshaft in it's
most forward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41 Nm plus a 1/4 Turn (30 ft. lbs.) plus a 1/4 Turn.
Remove the holding tool.
NOTE: Whenever an engine has been rebuilt, add one pint of Mopar(R) Engine Oil-Supplement or
equivalent to engine oil to aid in break in. The oil mixture should be left in engine for a minimum of
805 km (500 miles) and drained at the next normal oil change.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Removal and Installation > Page 1775
Crankshaft Main Bearing: Service and Repair Inspection
Main Journal Inspection
MAIN BEARINGS
Bearing caps are not interchangeable and should be marked at removal to insure correct
assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves
of 1, 3 and 4 are interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable.
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding
should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. Do NOT grind
thrust faces of Number 2 main bearing. Do NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts used is important that the final paper or cloth
polish after any journal regrind be in the same direction as normal rotation in the engine.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Removal and Installation > Page 1776
Upper and lower Number 2 bearing halves are flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed
during service procedures are to be cleaned and oiled before installation. Bearing shells are
available in standard and the following undersizes: 0.025 mm (0.001 inch), 0.051 mm (0.002 inch),
0.076 mm (0.003 inch), 0.254 mm (0.010 inch), and 0.305 mm (0.012 inch). Never install an
undersize bearing that will reduce clearance below specification.
Measuring Main Bearing Clearance
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use of Plastigage:
NOTE: The total clearance of the main bearings can only be determined by removing the weight of
the crankshaft. This can be accomplished by either of two methods:
Preferred Method Shimming the bearings adjacent to the bearing to be checked in order to remove
the clearance between upper bearing shell and the crankshaft. This can be accomplished by
placing a minimum of 0.254 mm (0.010 inch) shim (e.g. cardboard, match-book cover, etc.)
between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 20 Nm (10 - 15 ft. lbs.). The number of main bearing will vary from engine to engine. ^
When checking #1 main bearing shim # 2 main bearing.
^ When checking #2 main bearing shim #1 & #3 main bearing.
^ When checking #3 main bearing shim #2 & #4 main bearing.
^ When checking #4 main bearing shim #3 main bearing.
CAUTION: Remove all shims before reassembling engine.
Alternative Method The weight of the crankshaft can be supported by a jack under the
counterweight adjacent to the bearing being checked.
PLASTIGAGE PROCEDURE
1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately
6.35 mm (1/4 inch) off center and away from the
oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing being checked to the proper specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Removal and Installation > Page 1777
3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale
provided on the package. Locate the band closest
to the same width. This band shows the amount of clearance in thousandths of a millimeter.
Differences in readings between the ends indicate the amount of taper present. Record all readings
taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a
metric scale.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Page 1778
Crankshaft Main Bearing Remover and Installer C-3059
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Rebuild Specifications
Crankshaft: Specifications Rebuild Specifications
CRANKSHAFT
Type .....................................................................................................................................................
................................................. Cast Nodular Iron Bearings ...............................................................
................................................................................................................ Aluminum Lead (Bi - Metal)
Thrust Taken By ..................................................................................................................................
.............................................. No. 2 Main Bearing End Play ...............................................................
................................................................................................... 0.076 - 0.228 mm (0.003 - 0.009 in.)
Maximum Allowable (wear limit)
................................................................................................................................................... 0.381
mm (0.015 in.) Diametral Clearance Desired
................................................................................................................................ 0.018 - 0.076 mm
(0.0007 - 0.003 in.) Maximum Diametral Clearance (wear limit)
................................................................................................................................... 0.102 mm
(0.004 in.)
MAIN BEARING JOURNALS
Diameter ..............................................................................................................................................
................................................. 64 mm (2.519 in.) Maximum Out-of-Round and/or Taper
............................................................................................................................................ 0.025 mm
(0.001 in.) Bearings for Service ...........................................................................................................
......................................................................................... Std.
..............................................................................................................................................................
...................................... 0.025 mm (0.001 in.) ....................................................................................
................................................................................................................ 0.051 mm (0.002 in.) ..........
..............................................................................................................................................................
............................ 0.076 mm (0.003 in.) ..............................................................................................
...................................................................................................... 0.254 mm (0.010 in.) ....................
..............................................................................................................................................................
.................. 0.305 mm (0.012 in.)
CONNECTING ROD JOURNALS
Diameter ..............................................................................................................................................
................................................. 58 mm (2.283 in.) Maximum Out-of-Round and/or Taper
............................................................................................................................................ 0.025 mm
(0.001 in.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 1783
Crankshaft: Description and Operation
The nodular iron crankshaft is supported by four main bearings, with number two being the thrust
bearing. Crankshaft end sealing is provided by front and rear rubber seals.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 1784
Crankshaft: Service and Repair
DIAL INDICATOR
1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move
crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the
way to the front and read the dial indicator. Specifications: New Part: 0.09 to 0.24 mm (0.004 to
0.009 inch).
FEELER GAUGE
1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main
bearing cap and a crankshaft cheek using care not to
damage any bearing surface. Do not loosen main bearing cap.
2. Use a feeler gauge between number 2 thrust bearing and machined crankshaft surface to
determine end play. Refer to Specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Locations
Engine Block Heater: Locations
The power cord is located behind the radiator grille.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Locations > Page 1788
Engine Block Heater: Description and Operation
DESCRIPTION
The engine block heater is available as an optional accessory on all models. The heater is
operated by ordinary house current (110 Volt A.C.) through a power cord located behind the
radiator grille.
PURPOSE
This provides easier engine starting and faster warm-up when vehicle is operated in areas having
extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in
the engine block, with the heating element immersed in coolant.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Locations > Page 1789
Engine Block Heater: Service and Repair
REMOVAL
1. Drain coolant from radiator and cylinder block. 2. Remove power cord plug from heater. 3.
Loosen screw in center of heater. Remove heater assembly.
INSTALLATION
1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop
positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal.
4. Fill cooling system with coolant to the proper level, vent air, and inspect for leaks. Pressurize
system with Radiator Pressure Tool before looking
for leaks.
5. Install power cord plug to heater.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair
Expansion/Freeze Plug: Service and Repair
REMOVAL
Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup
plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug.
CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious
engine Problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with sealer. Make certain the new plug is cleaned of all oil or
grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least
0.5 mm (0.020 inch) inside the lead in chamfer. It is in not necessary to wait for curing of the
sealant. The cooling system can be refilled and the vehicle placed in service immediately.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Mounting Bolt .......................................................................................................................................
................................................... 54 Nm (40 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1796
Harmonic Balancer - Crankshaft Pulley: Service and Repair
CRANKSHAFT PULLEY REMOVAL
1. Disconnect battery. 2. Raise vehicle on hoist. 3. Remove right wheel ana inner splash shield. 4.
Remove drive belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair for procedure.
Fig. 41 Removing Crankshaft Pulley
5. Remove crankshaft pulley Fig. 41.
Fig. 42 Installing Crankshaft Pulley
CRANKSHAFT PULLEY INSTALLATION
1. Install crankshaft pulley Fig. 42. 2. Install drive belt. Refer to Engine/Drive Belts, Mounts,
Brackets and Accessories/Drive Belt/Service and Repair for installation procedure. B. Install inner
splash shield and wheel. 4. Connect battery.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1797
Puller 1023
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle
Piston: Technical Service Bulletins Engine - Piston Knock at Idle
NO: 09-03-94 GROUP: Engine DATE: Apr. 1, 1994
SUBJECT: Engine Idle Piston Noise
MODELS: 1990 - 1993
(AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1994 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1994 (LH) Concorde/intrepid/Vision
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 3.3L AND 3.8L ENGINE
SYMPTOM/CONDITION:
Cold start up piston knocking noise at idle that diminishes 3 to 5 minutes after start up. The
condition is more prominent in low ambient temperatures and after the vehicle has set overnight.
Similar symptoms are described in Technical Service Bulletin 09-21-93 dated Dec. 31, 1993,
"Carbon Buildup on Top of Piston". Refer to this Bulletin for additional details.
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 are present and all systems are functioning correctly, and carbon buildup on
the top of the piston is not evident, proceed with the following repair.
PARTS REQUIRED:
AR 4621978 Piston & Connecting Rod Assy. (use w/3.3L engine)
AR 4621981 Piston & Connecting Rod Assy. (use w/3.8L engine)
REPAIR PROCEDURE:
This repair involves installing a new coated piston and connecting rod assembly.
1. Following the procedure outlined in the appropriate Service Manual, remove the engine piston
and connecting rods.
2. Install the new coated piston and connecting rod assembly as outlined in the Service Manual.
NOTE:
HONING OF THE CYLINDER BORES IS NOT RECOMMENDED.
DISCUSSION:
The new pistons have a coating bonded only to the piston skirt that is black in appearance. This
new coating replaces the previously used tin coating.
Items of special interest include:
1. The new coated pistons are available in one size only and are serviced with the piston pin and
connecting rod as an assembly.
2. The new coated piston connecting rod assembly can be used to service all models listed and
can be replaced one at a time (complete engine sets are not required).
3. Tin coated pistons should not be used as replacements for the coated pistons.
4. The coating material is applied after the final piston machining process. Therefore, the step for
measuring the outside diameter of the piston to determine size or piston to bore clearance is not
required.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle > Page 1802
5. Measuring the inside diameter of the cylinder bore with a Bore Gauge is still required. Dial
Cylinder Bore Indicator, Tool C-119 available from Miller Special Tools, is recommended. Follow
the procedure outlined in the Service Manual.
If the cylinder bore measures larger than 3.664 inches (93.059 mm) for the 3.3L Engine, or 3.782
inches (96.059 mm) for the 3.8L Engine, the cylinder block will require replacement.
6. Piston installation into the cylinder bore may require slightly more pressure than that required for
non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit
with the cylinder bore.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
1990 - 1994 AC, AS, AY (W/3.3L or 3.8L Engine) Piston and Connecting Rod Replace
Labor Operation No.
09-70-01-91 One - Front Bank 4.2 Hrs.
09-70-01-92 One - Rear Bank 4.5 Hrs.
09-70-01-93 One - Each Bank 6.0 Hrs.
09-70-01-94 Each Additional 0.5 Hrs.
09-70-01-63 A/C Equipped 0.2 Hrs.
09-70-01-64 Power Steering Equipped (AS Only) 0.2 Hrs.
1993 - 1994 LH (w/3.3L or 3.8L Engine) Piston and Connecting Rod Replace
Labor Operation No.
09-70-01-95 One - Left Bank 4.1 Hrs.
09-70-01-96 One - Right Bank 3.7 Hrs.
09-70-01-97 One - Each Bank 5.2 Hrs.
09-70-01-98 Each Additional 0.5 Hrs.
09-70-01-63 A/C Equipped 0.3 Hrs.
FAILURE CODE: 58 - Noisy Cold Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Technical Service Bulletins > Page 1803
Piston: Specifications
PISTONS
Type Material .......................................................................................................................................
............................... Aluminum Alloy Tin Coated Clearance at Size Location
.................................................................................................................................... 0.025 - 0.057
mm (0.001 - 0.0022 in.) Weight (Std. Only) .........................................................................................
............................................................................................. 381 +/- 5 gms Pistons For Service ........
..............................................................................................................................................................
............... Standard Only
PISTON PINS
Type
..............................................................................................................................................................
Press Fit in Rod (Serviced as an Assembly) Diameter ........................................................................
.................................................................................................. 22.88 mm (0.9007 - 0.9009 in.)
Length ..................................................................................................................................................
................... 67.25 - 67.75 mm (2.648 - 2.667 in.) Clearance in Piston,
Light Thumb Push @ 70°F
........................................................................................................................... 0.006 - 0.019 mm
(0.0002 - 0.0007 in.)
Clearance in Rod .................................................................................................................................
........................................................ (Interference)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Technical Service Bulletins > Page 1804
Piston: Description and Operation
The pistons are cast aluminum alloy. Three rings are used. Piston pins, press fitted into place, join
the pistons to forged steel connecting rods.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation
Piston: Service and Repair Removal and Installation
NOTE: Heads and Oil Pan have to be removed first.
REMOVAL
1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from
cylinder block. Be sure to keep tops of pistons
covered during this operation. Pistons and connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod assemblies from the engine; rotate crankshaft so
that each connecting rod is centered in cylinder bore.
2. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if
necessary.
3. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push
each piston and rod assembly out of cylinder
bore.
NOTE: Be careful not to nick crankshaft journals.
4. After removal, install bearing cap on the mating rod.
INSTALLATION
1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1807
with oil ring rail gap.
2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the
rail gaps located as shown. 3. Immerse the piston head and rings in clean engine oil, slide the ring
compressor, over the piston and tighten with the special wrench. Be sure
position of rings does not change during this operation.
4. Install connecting rod bolt protectors on rod bolts.
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod
over the crankshaft journal.
6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide
connecting rod into position on connecting rod journal.
7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps.
Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lb.) Plus 1/4 turn.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1808
Piston: Service and Repair Disassembly and Assembly
Fig. 22 Piston Measurements
Fig. 23 Piston Ring Installation
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1809
Fig. 24 Piston Ring Installation
Fig. 25 Ring End Gap Orientation
When installing piston and rod assemblies notch in piston top must point toward front of engine.
Refer to Fig. 22 through 25 for piston measurements and ring installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1810
Piston: Service and Repair Fitting Pistons
The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90
degrees to piston pin at size location shown. Cylinder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft center line shown. Refer to specifications.
Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Type .....................................................................................................................................................
..................................................... Press Fit Into Rod Diameter ..........................................................
.................................................................................................................. 22.88 mm (0.9009 0.9007 inch) Length .............................................................................................................................
.......................................... 67.25 - 67.75 mm (2.648 - 2.667 inch) Clearance In Piston w/Light
Thumb Push@70°F .................................................................................................. 0.006 - 0.019
mm (0.0002 - 0.0007 inch) Clearance In Rod .....................................................................................
............................................................................................................ Interference
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications > Page 1814
Piston Pin: Description and Operation
The piston pin rotates in the piston only, and is retained by the press interference fit of the piston
pin in the connecting rod. The piston pin is not to be removed; damage to the piston may result.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
PISTON RINGS
Number of Rings Per Piston ................................................................................................................
............................................................................ 3
Compression .......................................................................................................................................
....................................................................... 2 Oil .............................................................................
................................................................................................................................................ 1 Oil
Ring Type
..................................................................................................................................................... 3 Piece, Steel Rail, Chrome - Face
Ring Width
Compression
.......................................................................................................................................................
1.46 - 1.5 mm (0.0575 - 0.0591 in.) Oil - Steel Rails ...........................................................................
............................................................................................ 0.510 mm (0.0201 in.)
Ring Gap
Compression
................................................................................................................................................. 0.300 0.550 mm (0.0118 - 0.0217 in.) Oil - Steel Rails
............................................................................................................................................... 0.250 1.00 mm (0.0098 - 0.0394 in.)
Ring Side Clearance
Compression
................................................................................................................................................. 0.030 0.095 mm (0.0012 - 0.0037 in.) Oil - Steel Rails
............................................................................................................................................. 0.014 0.226 mm (0.0005 - 0.0089 in.)
Service Rings - Ring Gap
Compression
................................................................................................................................................. 0.300 0.550 mm (0.0018 - 0.0217 in.) Oil - Steel Rails
............................................................................................................................................... 0.250 1.00 mm (0.0098 - 0.0394 in.)
Ring Side Clearance
Compression
................................................................................................................................................. 0.030 0.095 mm (0.0012 - 0.0037 in.) Oil - Steel Rails
............................................................................................................................................. 0.014 0.226 mm (0.0005 - 0.0089 in.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Service and Repair > Removal and Installation
Piston Ring: Service and Repair Removal and Installation
Fig. 17 Installing piston rings
Fig. 18 Positioning ring end gaps
Install piston rings as shown in Figs. 17 and 18.
PISTON RING-REMOVAL
1. ID mark on face of upper and intermediate piston rings must point toward piston crown.
Piston Rings - Removing Or Installing
2. Using a suitable ring expander, remove upper and intermediate piston rings. 3. Remove the
upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 4. Clean ring
grooves of any carbon deposits.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1820
Piston Ring: Service and Repair Fitting Piston Rings
1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
The ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge.
Refer to specifications.
2. Check piston ring to groove clearance. Refer to specification.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Adjustments
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters, no adjustment is necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Fuel Pressure Release Procedure - Typical
WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even
when the engine is OFF.
1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3.
Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose,
tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this
hose to
the fuel rail service port. Fuel pressure should bleed off into container.
5. Perform necessary fuel system service procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Rocker Arm and Shaft
Rocker Arm Assembly: Specifications Rocker Arm and Shaft
Bracket Bolt .........................................................................................................................................
............................................... 28 Nm (250 inch lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Rocker Arm and Shaft > Page 1832
Rocker Arm Assembly: Specifications
Rocker Arm Bolts 250 in.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1833
Rocker Arm Assembly: Description and Operation
Rocker arms are installed on a rocker arm shaft attached to the cylinder head with four bolts and
retainers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1834
Rocker Arm Assembly: Service and Repair
REMOVAL
1. Remove upper intake manifold assembly. Refer to Intake Manifold. 2. Disconnect spark plug
wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4.
Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6.
Remove rocker arms and shaft assembly. 7. If rocker arm assemblies are disassembled for
cleaning or replacement, re-assemble rocker arms in their original position.
INSTALLATION
1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions,
tighten to 28 Nm (250 in. lbs.).
CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts.
Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine
operation.
2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if
necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover
fasteners to 12 Nm (105 in. lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug
wires. 6. Install upper intake manifold assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Specifications
Valve Cover: Specifications
Cylinder Head Cover Bolts/Nuts 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Specifications > Page 1838
Valve Cover: Description and Operation
The covers are sealed with steel reinforced silicon rubber gaskets.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Specifications
Valve Guide: Specifications
Type .....................................................................................................................................................
............................................. Powdered Metal Inserts Guide Bore Diameter
................................................................................................................................................ 7.975 8.000 mm (0.314 - 0.315 inch) Intake Stem To Guide Clearance: New Valve ....................................
............................................................................................................................. 0.025 - 0.095 mm
(0.001 - 0.003 inch) Maximum Allowed Rocking Method
................................................................................................................................................ 0.247
mm (0.010 inch) Exhaust Stem To Guide Clearance: New Valve .......................................................
.......................................................................................................... 0.051 - 0.175 mm (0.002 0.006 inch) Maximum Allowed Rocking Method
................................................................................................................................................ 0.414
mm (0.016 inch)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Maximum Runout ................................................................................................................................
.............................................. 0.760 mm (0.003 inch) Intake:
Seat Angle ...........................................................................................................................................
............................................................ 45 - 45 1/2° Seat Width ..........................................................
....................................................................................................... 1.75 - 2.25 mm (0.069 - 0.088
inch)
Exhaust:
Seat Angle ...........................................................................................................................................
............................................................ 45 - 45 1/2° Seat Width ..........................................................
....................................................................................................... 1.50 - 2.00 mm (0.057 - 0.078
inch)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications > Page 1845
Valve Seat: Service and Repair
NOTE: The valve seats have a 45 to 45-1/2 degree face angle.
CAUTION: Remove metal from valve seat only. Do not remove metal from cylinder head.
VALVE SEATS
1. When refacing valve seats, it is important that the correct size valve guide pilot be used for
reseating stones. A true and complete surface must be
obtained.
2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed
0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian
blue
then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center
of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve
seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve
seat with a 65 degrees stone.
NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and
seat width are maintained. Otherwise cylinder head must be replaced.
4. When seat is properly positioned the width of intake seats should be 1.75 - 2.25 mm (0.69 0.088 inch). The width of the exhaust seats should be
1.50 - 2.00 mm (0.059 - 0.078 inch).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications > Page 1846
5. Check the valve spring installed height after refacing the valve and seat.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Specifications
Valve Spring: Specifications
Number ................................................................................................................................................
.............................................................................. 12 Free Length .....................................................
..................................................................................................................................... 48.5 mm
(1.909 inch) Wire Diameter ..................................................................................................................
................................................................... 4.75 mm (0.187 inch) Number of Coils ............................
..............................................................................................................................................................
...................... 6.8 Installed Height
.............................................................................................................................................................
41.2 - 42.7 mm (1.622 - 1.681 inch) Load When Compressed:
Valve Closed .......................................................................................................................................
...................................... 95 - 100 lbs. @1.570 inch Valve Open .........................................................
.................................................................................................................... 207 - 229 lbs. @1.169
inch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Specifications > Page 1850
Valve Spring: Description and Operation
Unique beehive style valve spring are used with lightweight retainers for improved high RPM
performance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head On
Valve Spring: Service and Repair Cylinder Head On
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable.
3. Remove Air Cleaner Cover and hose assembly.
4. Remove upper Intake Manifold.
5. Remove cylinder head covers and spark plugs.
6. Remove connector wire from ignition coils.
7. Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the
number 1 piston is at Top Dead Center on the compression stroke.
8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be
disturbed and left on shaft.
9. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to
100 psi air pressure (620.5 to 689 kPa). This is to hold valves into place while servicing
components.
10. Using Tool C-4682, or equivalent compress valve spring and remove retainer valve locks and
valve spring.
11. The intake valve stem seals should be pushed firmly and squarely over the valve guide using
the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer
locks, compress the spring only enough to install the locks.
CAUTION: Do not pinch seal between retainer and top of valve guide.
12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6.
Make sure piston in cylinder is at Top Dead Center (TDC) on the valve spring that is being covered.
13. Remove spark plug adapter tool.
14. Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 inch
lbs.).
15. Install cylinder head covers tighten screws to 14 Nm (120 inch lbs.) and connector to ignition
coils.
16. Install Intake Manifold.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head On > Page 1853
Valve Spring: Service and Repair Inspection
Whenever valves have been removed for inspection, reconditioning or replacement, valve springs
should be tested. As an example; the compression length of the spring to be tested is 33.34 mm
(1-5/16 inches). Turn table of Tool C-647, or equivalent until surface is in line with the 33.34 mm
(1-5/16 inch) mark on the threaded stud and the zero mark on the front. Place shrine over stud on
the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard.
Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring
load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer
to specifications to obtain specified height and allowable tensions. Discard the springs that do not
meet specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Page 1854
Valve Spring: Tools and Equipment
Valve Spring Tester C-647
Valve Spring Compressor C-3422-B
Valve Spring Compressor Adapter 6412
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
Intake Valve:
Stem Diameter .....................................................................................................................................
........................................ 7.935 mm (0.3124 inch) Face Angle ..........................................................
.................................................................................................................................................... 44
1/2° Margin ..........................................................................................................................................
................................................. 0.794 mm (0.031 inch) Head Diameter .............................................
...................................................................................................................................... 45.5 mm
(1.79 inch) Length ................................................................................................................................
.......................................................... 125.38 mm (4.936 inch) Lift (zero lash) ....................................
........................................................................................................................................... 10.16 mm
(0.400 inch) Minimum Valve Length After Grinding Tip
.............................................................................................................................. 124.892 mm
(4.916 inch)
Exhaust Valve:
Stem Diameter .....................................................................................................................................
........................................ 7.906 mm (0.3112 inch) Face Angle ..........................................................
.................................................................................................................................................... 44
1/2° Margin ..........................................................................................................................................
............................................... 1.191 mm (0.0469 inch) Head Diameter .............................................
.................................................................................................................................... 37.5 mm
(1.476 inch) Length ..............................................................................................................................
............................................................ 126.00 mm (4.964 inch) Lift (zero lash) ..................................
............................................................................................................................................. 10.16 mm
(0.400 inch) Minimum Valve Length After Grinding Tip
.............................................................................................................................. 125.512 mm
(4.941 inch)
Valve Timing:
Intake Opens .......................................................................................................................................
................................................................ 2° BTDC Intake Closes ......................................................
.............................................................................................................................................. 58°
ABDC Exhaust Opens .........................................................................................................................
......................................................................... 48° BBDC Exhaust Closes ........................................
..........................................................................................................................................................
12° ATDC Valve Overlap .....................................................................................................................
.......................................................................................... 14° Intake Valve Duration .........................
..............................................................................................................................................................
......... 240° Exhaust Valve Duration ....................................................................................................
.......................................................................................... 240°
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications > Page 1858
Valve: Testing and Inspection
INSPECTION
1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve
stems for wear. Refer to specifications. Valve stems are chrome plated and should not be polished.
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4.
Measure valve stem guide clearance as follows:
a. Install valve into cylinder head so it is 14 mm (0.551 inch) off the valve seat. A small piece of
hose may be used to hold valve in place.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications > Page 1859
b. Attach dial indicator Tool C-3339, or equivalent to cylinder head and set it at right angle of valve
stem being measured.
5. Move valve to and from the indicator. Refer to specifications. 6. Ream the guides for valves with
oversized stems if dial indicator reading is excessive or if the stems are scuffed or scored. 7.
Service valves with oversize stems and over size seals are available in 0.16 mm (0.005 inch), 0.40
mm, (0.015 inch) and 0.80 mm (0.030 inch)
oversize.
NOTE: Oversize seals must be used with oversize valves.
8. Reamers to accommodate the oversize valve stem are shown. 9. Slowly turn reamer by hand
and clean guide thoroughly before installing new valve. Do not attempt to ream the valve guides
from standard
directly to 0.80 mm (0.030 inch) Use step procedure of 0.15 mm (0.005 inch), 0.40 mm (0.015 inch)
and 0.80 mm (0.030 inch) so valve guides may be reamed true in relation to the valve seat. After
reaming guides, the seat runout should be measured and resurfaced if necessary.
NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize
reamer, or if guide is loose in cylinder head.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation
Valve: Service and Repair Removal and Installation
REMOVAL
1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412, or equivalent as shown. 2. Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure
installation in original location.
INSTALLATION
1. Coat valve stems with clean engine oil and insert them in cylinder head.
2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve
tip to give 49.541 - 51.271 mm (1.950 - 2.018
inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip
chamfer should be reground to prevent seal damage when the valve is installed.
3. Install valve spring seat spacer on head.
4. Install new cup seals on all valve stems and over valve guides. Install valve springs and valve
retainers. 5. Compress valve springs with Valve Spring Compressor Tool C-3422-B, with adapter
6412, or equivalents install locks and release tool. If valves
and/or seats are reground, measure the installed height of springs dimension B. make sure
measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is
greater than 1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1862
to bring spring height back to normal 1-17/32 - 1-19/32 inch (39.1 - 40.6 mm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1863
Valve: Service and Repair Refacing Valves and Valve Seats
The intake and exhaust valves have a 44-1/2 to 45 degree face angle. Inspect the remaining
margin after the valves are refaced Refer to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 070294A > Dec > 94
> Serpentine Drive Belt - Comes Off Pulleys
Drive Belt: Customer Interest Serpentine Drive Belt - Comes Off Pulleys
NO.: 07-02-94 Rev. A
GROUP: Cooling
DATE: Dec. 23, 1994
SUBJECT: Serpentine Drive Belt Comes Off Pulleys
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES
VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
**1992 - 1995 (ES) Chrysler Voyager (European Market)**
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of
its pulleys by snow coming in between the belt and the pulleys.
DIAGNOSIS:
Determine the road conditions the driver of the vehicle was encountering at the time the serpentine
belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are
properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor
in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley
attachment problem has been corrected, perform the following repair procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves attaching a shield to the power steering pump and the power steering pump
bracket that prevents snow from coming in between the serpentine belt and the power steering
pump pulley.
1. Re-install the serpentine drive belt or replace with a new belt if damaged.
2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the
engine block.
NOTE:
ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING
BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT
OFF. DO NOT BREAK THE TAB OFF.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 070294A > Dec > 94
> Serpentine Drive Belt - Comes Off Pulleys > Page 1873
3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield)
goes over the stud on the back of the power steering pump and the other mounting hole is aligned
with the hole of power steering pump bracket from which the bolt was removed in step 2.
4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m).
5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque
to 30 - 50 ft.lbs. (40.7 - 67.8 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
07-20-15-95 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys
Drive Belt: All Technical Service Bulletins Serpentine Drive Belt - Comes Off Pulleys
NO.: 07-02-94 Rev. A
GROUP: Cooling
DATE: Dec. 23, 1994
SUBJECT: Serpentine Drive Belt Comes Off Pulleys
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES
VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
**1992 - 1995 (ES) Chrysler Voyager (European Market)**
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of
its pulleys by snow coming in between the belt and the pulleys.
DIAGNOSIS:
Determine the road conditions the driver of the vehicle was encountering at the time the serpentine
belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are
properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor
in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley
attachment problem has been corrected, perform the following repair procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves attaching a shield to the power steering pump and the power steering pump
bracket that prevents snow from coming in between the serpentine belt and the power steering
pump pulley.
1. Re-install the serpentine drive belt or replace with a new belt if damaged.
2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the
engine block.
NOTE:
ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING
BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT
OFF. DO NOT BREAK THE TAB OFF.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys > Page 1879
3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield)
goes over the stud on the back of the power steering pump and the other mounting hole is aligned
with the hole of power steering pump bracket from which the bolt was removed in step 2.
4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m).
5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque
to 30 - 50 ft.lbs. (40.7 - 67.8 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
07-20-15-95 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1880
Drive Belt: Specifications
Belt tension is controlled automatically by the dynamic tensioner.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Diagrams > With A/C
Fig. 34 Serpentine Drive Belt Routing
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Diagrams > With A/C > Page 1883
Drive Belt: Diagrams Without A/C
Fig. 34 Serpentine Drive Belt Routing
This image shows an air conditioning compressor.
The OE does not provide an image for accessory belt routing without A/C.
This article is included here to provide the accessory drive belt routing for a non-air conditioned
vehicle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Diagrams > Page 1884
Drive Belt: Description and Operation
The accessory drive system utilizes two different style of drive belts. The conventional V-belt and
the Poly-v belt are used to drive the generator, air conditioning compressor, power steering pump
and water pump. Satisfactory performance of these belts depends on belt condition and proper belt
tension. Belt tensioning should be performed with the aid of a Burroughs gauge special tool
C-4162, or equivalent. Because of space limitations in the engine compartment, the use of the
gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain
access to the drive belts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Diagrams > Page 1885
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Diagrams > Page 1886
Drive Belt: Adjustments
PROPER BELT TENSION
Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt
tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because
of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the
vehicle on a hoist and the remove the splash shield to gain access to the drive belts.
BELT TENSION GAUGE METHOD
Use belt tensioning Special Tool Kit C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges
are not interchangeable.
For Conventional V-belts - affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the
belt tension for New or Used belt as prescribed in specifications.
For a Poly-V Belt - affix the Poly-V Burroughs gauge to the belt and then apply specified tension to
the belt as prescribed in specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation
Drive Belt: Service and Repair Removal and Installation
Fig. 6 Accessory Drive Belt
REMOVE/INSTALL
The Poly-V Drive belt is provided with a dynamic tensioner Fig. 6 to maintain proper belt tension.
To remove or install this belt:
1. Raise vehicle on hoist. 2. Remove right front splash shield. 3. Release tension by rotating the
tensioner clockwise Fig. 6. 4. Reverse above procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1889
Drive Belt: Service and Repair Cleaning and Inspection
When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt
from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal. Any belt with cracks running along the rib must
be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Page 1890
Belt Tension Gauge C-4162
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Service and Repair
Drive Belt Tensioner: Service and Repair
The tensioner is attached by stud through the bracket with a nut on the back of the bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Specifications
Engine Accessory Bracket: Specifications
A/C Compressor Bracket to Water Pump Bolt
......................................................................................................................................... 41 Nm (30
ft. lbs.) A/C Compressor To Bracket Bolt
.............................................................................................................................................................
67 Nm (50 ft. lbs.) A/C Compressor Support Bolts ..............................................................................
.................................................................................. 41 Nm (30 ft. lbs.) Generator:
Adjusting Strap Bolt .............................................................................................................................
........................................... 23 Nm (200 inch lbs.) Adjusting Strap Mounting Bolt
.............................................................................................................................................................
41 Nm (30 ft. lbs.) Bracket Bolt ............................................................................................................
.............................................................................. 41 Nm (30 ft. lbs.) Mounting Pivot Nut ..................
............................................................................................................................................................
41 Nm (30 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 >
Aug > 94 > Engine Mount - Squeak/Clunk Noise
Technical Service Bulletin # 091494 Date: 940809
Engine Mount - Squeak/Clunk Noise
NO.: 09-14-94
GROUP: Engine
DATE: Sep. 9, 1994
SUBJECT: Squeak Noise When Turning and/or Clunk Noise When Shifting Into Reverse
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
1. Squeak noise from the engine compartment which occurs during a low speed right turn. The
squeak noise becomes more pronounced when the road surface is rough and/or while accelerating
during the turn.
2. Squeak noise from the engine compartment which occurs during a low speed left turn. The
squeak noise becomes more pronounced when the road surface is rough and/or while accelerating
during the turn.
3. Clunk noise from the engine compartment which occurs when shifting transmission into reverse.
Symptom/Condition 1
The squeak noise during right turns can be caused by the top edge of the left engine mount
rubbing on the left frame rail bracket, or the outside of the front engine mount rubbing on the
drivers side of the bracket which ties it to the engine.
Inspect the left engine mount visually for a bare metal spot where the paint has been rubbed off of
the engine bracket and by the relative position between the core of the rubber isolator and the nub
on the gold "slider tube" (Refer to Figure 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 >
Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1905
Inspect the front engine mount visually for a bare metal spot where the paint has been rubbed off of
the left rail bracket (Refer to Figure 2). If the bare metal spot is present, perform repair procedure 1.
Symptom/Condition 2
The squeak noise during left turns can be caused by the outside of the front engine mount rubbing
on the passenger side of the bracket which ties it to the engine. Inspect the front engine mount
visually for a bare metal spot where the paint has been rubbed off of the engine bracket (Refer to
Figure 3). If the bare metal spot is present, perform repair procedure 1.
Symptom/Condition 3
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 >
Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1906
A clunk noise while shifting into reverse can be caused by relative movement between the metal
can which the front engine mount isolator is molded around and the square metal can which is
welded to the bracket which the isolator can is pressed into (Refer to Figure 4).
To diagnose the front mount, fully apply the parking brake and service brakes. Watch and listen to
the front mount while an assistant shifts the transmission into reverse and slowly increases the
throttle opening (brake torque). It will be visually apparent if the inner isolator can moves relative to
the outer can causing an audible clunk noise during this maneuver. If the vehicle exhibits this
condition, perform repair procedure 2.
Repair Procedure 1
This procedure corrects Symptom/Condition 1 & 2 by adjusting the right and front engine mounts.
1. Verify the front driveshaft lengths (engine centering) are within specification. Measure the length
from the inner edge of the outboard boot to the inner edge of the inboard boot on both driveshafts
(Refer to Figure 5). This measurement must be taken at the bottom (six o'clock position) of the
driveshafts while the vehicle is in a normal parked, front wheels straight ahead position.
Driveshaft Length Specifications:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 >
Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1907
2. Remove the load on the engine mounts by carefully supporting the engine and transmission with
a floor jack.
3. Loosen the 2 bolts attaching the right engine mount insulator to the frame rail.
4. Loosen the screw and 2 nuts attaching the front engine mount bracket to the front lower
crossmember.
5. If the driveshaft lengths are within specification, skip to step 6. Otherwise, loosen the left engine
mount through bolt so it is still engaged in the threads weld nut of the rail bracket. Pry the engine
right or left as required to achieve the proper driveshaft lengths. Make sure the left engine mount
two piece gold color slider tube moves in relation to the aluminum core for the adjustment to be
effective.
6. Position the right engine mount insulator so an outboard gap "A" of .020 in. (0.5 mm) is achieved
between the outboard snubber of the insulator and the yoke bracket (Refer to Figure 6). Torque the
2 right engine mount insulator attaching bolts to 50 ft.lbs. (68 N-m).
7. Position the front engine mount isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the
drivers side and 0.5 in. (12 mm) on the
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 >
Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1908
passengers side between the isolator and the engine bracket (Refer to Figure 7).
NOTE:
IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.1
in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF
NECESSARY, BY USING A RAT TAIL FILE.
Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front
crossmember to 40 ft.lbs. (54 N-m).
8. If driveshaft length adjustment was required, torque the left engine mount through bolt to 55
ft.lbs. (75 N-m) and recheck driveshaft lengths.
9. Apply touch up paint to any bare metal spots.
Repair Procedure 2
This procedure corrects Symptom/Condition 3 by replacing the front engine mount isolator.
1. Support the engine and transmission assembly with a floor jack so it will not rotate when the
mount is disconnected from the lower front crossmember.
2. Remove the screw and 2 nuts attaching the front engine mount insulator to the lower front
crossmember.
3. Remove the through bolt attaching the front engine mount insulator to the front engine bracket
and discard the insulator.
4. Select the appropriate front engine mount insulator from the Parts Required section of this
bulletin. Install the through bolt attaching the front engine mount insulator to the front engine
bracket. Torque the through bolt to 50 ft. lbs. (68 Nm). Position the replacement front engine mount
isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the drivers side and 0.5 in. (12 mm)
on the passengers side between the isolator and the engine bracket (Refer to Figure 7).
NOTE:
IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.08
in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF
NECESSARY, BY USING A RAT TAIL FILE.
5. Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front
crossmember to 40 ft.lbs. (54 N-m).
Policy
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
09-40-23-92 (Condition 1) 0.7 Hrs.
09-40-23-91 (Condition 2) 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment (Condition 1)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 >
Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1909
P8 - New Part (Condition 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise
Technical Service Bulletin # 091494 Date: 940809
Engine Mount - Squeak/Clunk Noise
NO.: 09-14-94
GROUP: Engine
DATE: Sep. 9, 1994
SUBJECT: Squeak Noise When Turning and/or Clunk Noise When Shifting Into Reverse
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
1. Squeak noise from the engine compartment which occurs during a low speed right turn. The
squeak noise becomes more pronounced when the road surface is rough and/or while accelerating
during the turn.
2. Squeak noise from the engine compartment which occurs during a low speed left turn. The
squeak noise becomes more pronounced when the road surface is rough and/or while accelerating
during the turn.
3. Clunk noise from the engine compartment which occurs when shifting transmission into reverse.
Symptom/Condition 1
The squeak noise during right turns can be caused by the top edge of the left engine mount
rubbing on the left frame rail bracket, or the outside of the front engine mount rubbing on the
drivers side of the bracket which ties it to the engine.
Inspect the left engine mount visually for a bare metal spot where the paint has been rubbed off of
the engine bracket and by the relative position between the core of the rubber isolator and the nub
on the gold "slider tube" (Refer to Figure 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1915
Inspect the front engine mount visually for a bare metal spot where the paint has been rubbed off of
the left rail bracket (Refer to Figure 2). If the bare metal spot is present, perform repair procedure 1.
Symptom/Condition 2
The squeak noise during left turns can be caused by the outside of the front engine mount rubbing
on the passenger side of the bracket which ties it to the engine. Inspect the front engine mount
visually for a bare metal spot where the paint has been rubbed off of the engine bracket (Refer to
Figure 3). If the bare metal spot is present, perform repair procedure 1.
Symptom/Condition 3
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1916
A clunk noise while shifting into reverse can be caused by relative movement between the metal
can which the front engine mount isolator is molded around and the square metal can which is
welded to the bracket which the isolator can is pressed into (Refer to Figure 4).
To diagnose the front mount, fully apply the parking brake and service brakes. Watch and listen to
the front mount while an assistant shifts the transmission into reverse and slowly increases the
throttle opening (brake torque). It will be visually apparent if the inner isolator can moves relative to
the outer can causing an audible clunk noise during this maneuver. If the vehicle exhibits this
condition, perform repair procedure 2.
Repair Procedure 1
This procedure corrects Symptom/Condition 1 & 2 by adjusting the right and front engine mounts.
1. Verify the front driveshaft lengths (engine centering) are within specification. Measure the length
from the inner edge of the outboard boot to the inner edge of the inboard boot on both driveshafts
(Refer to Figure 5). This measurement must be taken at the bottom (six o'clock position) of the
driveshafts while the vehicle is in a normal parked, front wheels straight ahead position.
Driveshaft Length Specifications:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1917
2. Remove the load on the engine mounts by carefully supporting the engine and transmission with
a floor jack.
3. Loosen the 2 bolts attaching the right engine mount insulator to the frame rail.
4. Loosen the screw and 2 nuts attaching the front engine mount bracket to the front lower
crossmember.
5. If the driveshaft lengths are within specification, skip to step 6. Otherwise, loosen the left engine
mount through bolt so it is still engaged in the threads weld nut of the rail bracket. Pry the engine
right or left as required to achieve the proper driveshaft lengths. Make sure the left engine mount
two piece gold color slider tube moves in relation to the aluminum core for the adjustment to be
effective.
6. Position the right engine mount insulator so an outboard gap "A" of .020 in. (0.5 mm) is achieved
between the outboard snubber of the insulator and the yoke bracket (Refer to Figure 6). Torque the
2 right engine mount insulator attaching bolts to 50 ft.lbs. (68 N-m).
7. Position the front engine mount isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the
drivers side and 0.5 in. (12 mm) on the
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1918
passengers side between the isolator and the engine bracket (Refer to Figure 7).
NOTE:
IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.1
in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF
NECESSARY, BY USING A RAT TAIL FILE.
Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front
crossmember to 40 ft.lbs. (54 N-m).
8. If driveshaft length adjustment was required, torque the left engine mount through bolt to 55
ft.lbs. (75 N-m) and recheck driveshaft lengths.
9. Apply touch up paint to any bare metal spots.
Repair Procedure 2
This procedure corrects Symptom/Condition 3 by replacing the front engine mount isolator.
1. Support the engine and transmission assembly with a floor jack so it will not rotate when the
mount is disconnected from the lower front crossmember.
2. Remove the screw and 2 nuts attaching the front engine mount insulator to the lower front
crossmember.
3. Remove the through bolt attaching the front engine mount insulator to the front engine bracket
and discard the insulator.
4. Select the appropriate front engine mount insulator from the Parts Required section of this
bulletin. Install the through bolt attaching the front engine mount insulator to the front engine
bracket. Torque the through bolt to 50 ft. lbs. (68 Nm). Position the replacement front engine mount
isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the drivers side and 0.5 in. (12 mm)
on the passengers side between the isolator and the engine bracket (Refer to Figure 7).
NOTE:
IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.08
in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF
NECESSARY, BY USING A RAT TAIL FILE.
5. Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front
crossmember to 40 ft.lbs. (54 N-m).
Policy
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
09-40-23-92 (Condition 1) 0.7 Hrs.
09-40-23-91 (Condition 2) 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment (Condition 1)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1919
P8 - New Part (Condition 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 1920
Engine Mount: Adjustments
1. Remove the load on the engine motor mounts by carefully supporting the engine and
transmission assembly with a floor jack. 2. Loosen the right engine mount insulator vertical fastener
and the fore and aft fasteners, and the front engine mount bracket to front crossmember
screws.
3. Pry the engine right or left as required to achieve the proper drive shaft assembly length. 4.
Tighten engine mounts and fasteners in the following order:
a. Right engine mount insulator vertical bolts to 102 Nm (75 ft. lbs.) and the fore and aft bolts to
150 Nm (110 ft. lbs.). b. Front engine mount screws to 54 Nm (40 ft. lbs.) the clearance between
the snubbers and the engine should be 2 mm (0.078 inch) each side. c. Left engine mount through
bolt to 75 Nm (55 ft. lbs.).
5. Recheck driveshaft length.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount
Engine Mount: Service and Repair Engine Mount
FRONT
1. Raise and support vehicle. Support engine and transmission assembly with jack.
Fig. 2 Front Engine Mount Replacement
2. Remove front engine mount through bolt from insulator and front crossmember mounting
bracket, Fig. 2. 3. Remove six screws from air dam to access front mount screws. 4. Remove front
engine mount screws and remove insulator assembly. 5. Remove front mounting bracket. 6.
Reverse procedure to install, noting the following:
a. Torque bolts No. 1 and No. 5, Fig. 2, first to 40 ft. lbs., then torque bolts No. 2, No. 3 and No. 4
to 80 ft. lbs. b. Torque air dam screws to 8.75 ft. lbs.
LEFT
1. Raise and support vehicle, then remove left front wheel. 2. Support transaxle with suitable jack.
3. Remove insulator through bolt from left engine mount.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount > Page 1923
Fig. 3 Left Side Engine Mount Replacement
4. Remove mount to transmission fasteners, then remove mount, Fig. 3. 5. Reverse procedure to
install, noting the following:
a. Tighten attaching nuts and bolts to specifications. b. Before tightening through bolt ensure there
is no load on insulator.
RIGHT
1. Remove purge duty solenoid and wiring harness from engine mount bracket.
Fig. 4 Right Side Engine Mount Replacement
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount > Page 1924
2. Remove two right engine mount insulator vertical bolts from frame rail and loosen horizontal bolt.
Do not remove large nut at end of core, Fig.
4.
3. Support transaxle with suitable jack. 4. Remove vertical and horizontal bolts from engine side
bracket, then remove mount assembly. 5. Reverse procedure to install. Tighten to specifications.
REAR
1. Raise and support vehicle, then remove left front wheel. 2. Support transmission with
transmission jack. 3. Remove insulator through bolt from mount and rear suspension
crossmember.
Fig. 5 Rear Engine Mount Replacement
4. Remove four transmission mount bolts and the mount, Fig. 5. 5. Reverse procedure to install.
Torque through bolt to 55 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount > Page 1925
Engine Mount: Service and Repair Rubber Insulators
Insulator location on (right side) is adjustable to allow right/left drive train adjustment in relation to
drive shaft assembly length. Check and reposition right engine mount insulator. See Adjustments.
Adjust drive train position, if required, for the following conditions:
a. Drive shaft distress. b. Any front end structural damage (after repair). c. Insulator replacement.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Testing and Inspection
Engine Oil Pressure: Testing and Inspection
Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5
psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM.
1. Remove pressure sending unit and install oil pressure gauge.
CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM.
2. Warm engine at high idle until thermostat opens.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug >
Component Information > Specifications
Engine Oil Drain Plug: Specifications
Drain Plug ............................................................................................................................................
..................................................... 34 Nm (25 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications
Engine Oil: Specifications
TYPE....................................................................................................................................................
...............................................................SG, SG/CD*
*Preferred with Turbo engine SG/CD required for 1993 Turbo engine.
CAPACITY, Refill: 3.3L Concorde, Intrepid, Vision
...................................................................................................................................................... 4.3
Liters 4.5 Quarts
3.5L, all ................................................................................................................................................
........................................... 4.8 Liters 5.0 Quarts
All others ..............................................................................................................................................
........................................... 3.8 Liters 4.0 Quarts
Capacity shown is without filter. When replacing filter, additional oil may be needed
All engine. above 0°F (-18°C)...............................................................................................................
.....................................................................10W-30* 2.5L Van, 3.5L & Turbo below 32°F (0°C)........
.........................................................................................................................................................5
W-30‡
Non-Turbo ex. 2.5L Van below 100°F (38°C).......................................................................................
........................................................................5W-30 *Preferred in all Turbo, 2.5L & 3.5L ‡Preferred
in all non-Turbo ex. 2.5L Van
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Service Precautions > Technician Safety Information
Engine Oil: Technician Safety Information
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID
PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED
ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR
HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN
RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR
DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Service Precautions > Technician Safety Information > Page 1938
Engine Oil: Vehicle Damage Warnings
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Service Precautions > Page 1939
Engine Oil: Description and Operation
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service
Grade SH or SH/CD.
SAE VISCOSITY
An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single
viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE
viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil
that is best suited to your particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. They are designated as
either ENERGY CONSERVING or ENERGY CONSERVING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been adopted to aid in the proper selection of
engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top
of engine oil cans.
ENGINE OIL ADDITIVES
In some instances, such as infrequent operation, short trip driving, and during break-in after a
major overhaul, addition of special materials containing anti-rust and anti-scuff additives are
beneficial.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Service Precautions > Page 1940
Engine Oil: Testing and Inspection
CHECKING OIL LEVEL
To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check
the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is
about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has
sat overnight. Checking the oil while the vehicle is on level ground, will improve the accuracy of the
oil level readings. Maintain the oil level between the MIN and MAX markings on the dipstick.
Adding one quart of oil when the reading is at the MIN mark will result in a MAX reading on these
engines.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Service Precautions > Page 1941
Engine Oil: Service and Repair
CHANGING ENGINE OIL
Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface
and turn engine off. 2. Hoist and support vehicle on safety stands. Refer. to Hoisting and Jacking
Recommendations. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5.
Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain
plug and gasket if damaged.
6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and
amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Service and Repair
Oil Filter: Service and Repair
CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install
tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is
reinforced by the base plate.
1. Using Tool C-4065, or equivalent, turn filter counterclockwise to remove from base. Properly
discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new
filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighter filter 1 turn or 20
Nm (15 ft. Lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Service and Repair > Page 1945
Oil Filter Wrench C-4065
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Specifications
Oil Filter Adapter: Specifications
Mounting Bolt .......................................................................................................................................
................................................... 41 Nm (30 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Oil Pan Bolts 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal and Installation
Oil Pan: Service and Repair Removal and Installation
REMOVAL
1. Disconnect battery negative cable, remove engine oil dipstick. 2. Raise vehicle. Drain engine-oil.
3. Remove oil pan screws and remove oil pan. 4. Remove screw for oil pick-up tube and remove
pick-up tube.
INSTALLATION
1. Install oil pick-up tube into Chain Case Cover tighten screw to 28 Nm (250 inch lbs.).
2. Apply a 1/8 inch bead of Mopar (R) Silicone Rubber Adhesive Sealant or equivalent, at the
parting line of the chain case cover and the rear seal
retainer.
3. Use a new pan gasket. 4. Install pan and tighten screws to 12 Nm (105 inch lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal and Installation > Page 1957
5. Lower vehicle and install oil dipstick. 6. Connect battery negative cable. 7. Fill crankcase with oil
to proper level.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal and Installation > Page 1958
Oil Pan: Service and Repair Cleaning and Inspection
1. Clean oil pan in solvent and wipe dry with a clean cloth. Clean all gasket material from mounting
surfaces of pan and block. 2. Inspect oil drain plug and plug hole for stripped or damaged threads
and repair as necessary. Install a new drain plug gasket. Tighten to 27 Nm (20
ft. lbs.).
3. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. 4. Clean
oil screen and pipe in clean solvent. Inspect condition of screen.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1964
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1965
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1966
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1967
Oil Pressure Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1968
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component
Information > Specifications
Oil Pump Cover: Specifications
Mounting Bolts .....................................................................................................................................
............................................... 12 Nm (105 inch lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer >
Component Information > Specifications
Oil Pick Up/Strainer: Specifications
Mounting Bolt .......................................................................................................................................
.............................................. 28 Nm (250 inch lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Testing and Inspection
Engine Oil Pressure: Testing and Inspection
Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5
psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM.
1. Remove pressure sending unit and install oil pressure gauge.
CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM.
2. Warm engine at high idle until thermostat opens.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Mounting Bolts .....................................................................................................................................
............................................... 23 Nm (200 inch lbs.) Plenum Bolt ......................................................
................................................................................................................................... 28 Nm (250
inch lbs.) Plenum Support Bracket ......................................................................................................
..................................................................... 54 Nm (40 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1982
Intake Manifold: Description and Operation
The intake manifold is a tuned two-piece semi-permanent mold aluminum casting with individual
primary runners leading from a plenum to the cylinders. The manifold is designed to boost torque in
the 3600 rpm range and contributes to the engine's broad, flat torque curve, which was desired for
excellent engine tractability, response and usable power output. The intake manifold is also cored
with upper level EGR passages for balanced cylinder to cylinder EGR distribution.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1983
Intake Manifold: Testing and Inspection
LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN
A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR
THE FAN. DO NOT WEAR LOOSE CLOTHING.
1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If
a change in RPM'S, the area of the suspected leak has been found. 4. Repair as required.
GENERAL INSPECTION
Check for: ^
Damage and cracks of each section.
^ Clogged water passages in end crossovers (if equipped).
^ Check for cylinder head mounting surface distortion using a straightedge and thickness gauge.
CLEANING
Remove the gasket material from the manifold surfaces. Be careful not to gouge or scratch the
sealing surface.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1984
Intake Manifold: Service and Repair
REMOVAL
1. Perform fuel system pressure release procedure, as follows.
NOTE: The fuel system is under a constant pressure of approximately 330 kPa (48 psi). Before
servicing the fuel pump, fuel lines, fuel filter, throttle body or fuel injector, the fuel system pressure
must be released.
Fig. 1 Injector Harness Connector
^ Loosen fuel filler cap to release fuel tank pressure.
^ Disconnect injector wiring harness, from engine harness.
^ Connect a jumper wire to ground terminal Number 1 of the injector harness Fig. 1 to engine
ground.
^ Connect a jumper wire to the positive terminal Number 2 of the injector harness Fig. 1 and touch
the battery positive post for no longer than 5 seconds. This releases system pressure.
^ Remove jumper wires.
^ Continue fuel system service.
2. Disconnect negative battery cable. Drain cooling system.
Fig. 2 Throttle Body Assembly 3.3L
3. Remove air cleaner to throttle body hose assembly Fig. 2.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1985
Fig. 3 Throttle Cable Attachment
4. Remove throttle cable Fig. 3. Remove wiring harness from throttle cable bracket.
Fig. 4 Electrical And Vacuum Connection To Throttle Body
5. Remove automatic idle speed (AIS) motor and throttle position sensor (TPS) wiring connectors
from throttle body Fig. 4. 6. Remove vacuum hose harness from throttle body Fig. 4.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1986
Fig. 5 Electrical And Vacuum Connections To Intake Manifold
7. Remove PCV and brake booster hoses from air intake plenum Fig. 5 8. Remove EGR tube
flange from intake plenum Fig. 5. 9. Disconnect Charge Temperature Sensor electrical connector.
Remove vacuum harness connectors from intake plenum Fig. 5.
10. Remove cylinder head to intake plenum strut Fig. 5.
Fig. 6 MAP Sensor Electrical Connector
11. Disconnect MAP Sensor and heated Oxygen Sensor electrical connection. Remove the engine
mounted ground strap Fig. 6.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1987
Fig. 7 Quick Connect Fuel Fittings To Fuel Rail
12. Remove the fuel hose quick connect fittings from the fuel rail by using an open end wrench
pushing in on the plastic ring located on the end of the
fittings. Gently pull the fittings from the fuel rail Fig. 7.
WARNING: Wrap a shop towel around hoses to catch any gasoline spillage during removal.
Fig. 8 Ignition Coils
13. Remove direct ignition system (DIS) coils and alternator bracket to intake manifold bolt Fig. 8.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1988
Fig. 9 Intake Manifold Bolts
14. Remove intake manifold bolts and rotate manifold back over rear valve cover Fig. 9.
Fig. 10 Fuel Rail Attaching Bolts
15. Cover intake manifold with suitable cover when servicing Fig. 10. 16. Remove vacuum harness
connector from Fuel Pressure Regulator. 17. Remove fuel tube retainer bracket screw and fuel rail
attaching bolts Fig. 10. Spread the retainer bracket to allow fuel tube removal clearance.
Fig. 11 Fuel Injector Wiring Clip
18. Remove fuel rail injector wiring clip from the alternator bracket Fig. 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1989
19. Disconnect cam sensor, coolant temperature sensor, and engine temperature sensors Fig. 11.
20. Remove fuel injector wiring clip from intake manifold water tube.
Fig. 12 Fuel Rail Removal
21. Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their
port Fig. 12.
Fig. 13 Intake Manifold Removal And Installation
22. Remove upper radiator hose, bypass hose and rear intake manifold hose Fig. 13. 23. Remove
intake manifold bolts. Remove intake manifold.
Fig. 14 Intake Manifold Gasket
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1990
24. Remove intake manifold seal retainers screws Fig. 14. Remove intake manifold gasket.
INSPECTION
Check for: ^
Damage and cracks of each section.
^ Clogged water passages in end crossovers.
INSTALLATION
1. Clean all surfaces of cylinder block and cylinder heads.
Fig. 15 Intake Manifold Gasket Sealing
2. Place a drop (approximately 1/4 in. diameter) of Mopar Silicone Rubber Adhesive Sealant or
equivalent, onto each of the four manifold to
cylinder head gasket corners Fig. 15.
WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury.
Handle with care.
3. Carefully install the intake manifold gasket Fig. 14. Torque end seal retainer screws to 12 Nm
(105 in.lbs.). 4. Install intake manifold and 8 bolts and torque to 1 Nm (10 in.lbs.). Then retorque
bolts to 22 Nm (200 in.lbs.) in sequence shown in Fig. 13. Then
retorque again to 22 Nm (200 in.lbs.). After intake manifold is in place, inspect to make sure seals
are in place.
5. Make sure the injector holes are clean and all plugs have been removed. 6. Lube injector O-ring
with a drop of clean engine oil to ease installation. 7. Put the tip of each injector into their ports.
Push the assembly into place until the injectors are seated in the ports Fig. 12. 8. Install the 4 fuel
rail attaching bolts and torque to 22 Nm (200 in.lbs.) Fig. 10. 9. Install fuel tube retaining bracket
screw and torque to 4 Nm (35 in.lbs.) Fig. 10.
10. Reconnect cam sensor, coolant temperature sensor and engine temperature sensors Fig. 11.
11. Install fuel injector harness wiring clips on the alternator bracket and intake manifold water tube
Fig. 11. 12. Connect fuel pressure regulator vacuum line. 13. Remove covering on lower intake
manifold and clean surface. 14. Place intake manifold gasket on lower manifold. Put upper
manifold into place and install bolts finger tight. 15. Install the alternator bracket to intake manifold
bolt and the cylinder head to intake manifold strut bolts. (Do not torque). 16. Torque intake manifold
bolts to 28 Nm (250 in.lbs.) following torque sequence in Fig. 9. 17. Torque alternator bracket to
intake manifold bolt to 54 Nm (40 ft.lbs.) Fig. 8. 18. Torque the cylinder head to intake manifold
strut bolts to 54 Nm (40 ft.lbs.) Fig. 5. 19. Connect ground strap, MAP and heated oxygen sensor
electrical connectors Fig. 6. 20. Connect charge temperature sensor electrical connector Fig. 5. 21.
Connect vacuum harness to intake plenum Fig. 5. 22. Using a new gasket, connect the EGR tube
flange to the intake manifold and torque to 22 Nm (200 in.lbs.). 23. Clip wiring harness into the hole
in the throttle cable bracket. 24. Connect the wiring connectors to the throttle position sensor (TPS)
and Automatic Idle Speed (AIS) motor Fig. 4. 25. Connect vacuum harness to throttle body Fig. 4.
26. Install the direct ignition system (DIS) coils. Torque fasteners to 12 Nm (105 in.lbs.) Fig. 8. 27.
Lubricate the ends of the chassis fuel tubes with 30 WT. oil. Connect fuel supply and return hoses
to chassis fuel tube assembly. Pull back on the
quick connect fitting to ensure complete insertion Fig. 7.
28. Install throttle cable Fig. 3. 29. Connect fuel injector wiring harness. 30. Install air cleaner and
hose assembly Fig. 2. 31. Connect negative battery cable. Fill Cooling System. See Cooling
System/Service and Repair.
See: Cooling System/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1991
32. With the DRB II use ASD Fuel System Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test, The Auto Shutdown (ASD) relay will remain
energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is
selected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Testing and Inspection
Crankshaft Main Bearing Seal: Testing and Inspection
Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The following steps should be followed to help
pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area:
1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover
and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak
is present in this area remove transmission for further inspection. a. Circular spray pattern
generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight
down, possible causes are a porous block, oil galley cup plug, bedplate to cylinder block mating
surfaces
and seal bore. See proper repair procedures for these items.
4. If no leaks are detected, pressurized the crankcase.
CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while slowly
turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the
crankshaft could have minor nicks or scratches that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially machined to complement the function of the
rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until
disassembled. 7. After the oil leak root cause and appropriate corrective action have been
identified. Replace rear main seal.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Testing and Inspection > Page 2000
Crankshaft Main Bearing Seal: Service and Repair
REMOVAL
1. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal.
Angle the pry tool through the dust lip against
metal case of the seal. Pry out seal.
CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry
tool blade against crankshaft edge (chamfer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installation of new seal.
1. Place Special Seal Pilot Tool C-4681, or equivalent on crankshaft. 2. Lightly coat seal O.D. with
Loctite Stud N' Bearing Mount or equivalent. 3. Place seal over Special Seal Pilot Tool C-4, or
equivalent and tap in place with a plastic hammer.
REAR CRANKSHAFT SEAL RETAINER
When retainer removal is required, remove retainer and clean engine block and retainer of old
gasket. Make sure surfaces are clean and free of oil. Install new gasket and tighten screws to 12
Nm (105 inch lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Testing and Inspection > Page 2001
Rear Crankshaft Seal Pilot Tool C-4681
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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. 6 Cylinder Head Assembly
DESCRIPTION
The aluminum alloy cylinder heads shown in Fig. 6 are held in place by 9 bolts. The spark plugs
are located in peak of the wedge between the valves.
REMOVAL
1. Drain cooling system and disconnect negative battery cable. Remove intake manifold, and
throttle body. Refer to Engine/Intake
Manifold/Service and Repair. See: Intake Manifold/Service and Repair
2. Disconnect coil wires, sending unit wire, heater hoses and by-pass hose. 3. Remove closed
ventilation system, evaporation control system and cylinder head covers. 4. Remove exhaust
manifolds. 5. Remove rocker arm and shaft assemblies. Remove push rods and identify to insure
installation in original locations.
Fig. 7 Cylinder Head Bolts Location
6. Remove the 9 head bolts from each cylinder head and remove cylinder heads Fig. 7.
INSPECTION
1. Before cleaning, check for leaks, damage and cracks. 2. Clean cylinder head and oil passages.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 2006
Fig. 8 Check Cylinder Head
3. Check cylinder head for flatness Fig. 8. 4. Inspect all surfaces with a straightedge if there is any
reason to suspect leakage. If out of flatness exceeds 0.019 mm (0.00075 inch). times the
span length in inches in any direction, either replace head or lightly machine the head surface. As
an example, if a 12 inch span is 1 mm (0.004 inch) out of flat, allowable is 12 x 0.019 mm (0.00075
inch) equals 0.22 mm (0.009 in.). This amount of out of flat is acceptable.
NOTE: Maximum of 0.2 mm (0.008 inch) for grinding is permitted.
CAUTION: This is a combined total dimension of stock removal from cylinder head and block top
surface.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 2007
Cylinder Head Gasket: Service and Repair Cylinder Head Installation
Fig. 29 Head Gasket Installation
INSTALLATION
1. Clean all surfaces of cylinder block and cylinder heads. 2. Install new gaskets on cylinder block
Fig. 29.
Fig. 30 Checking Bolts For Stretching (Necking)
3. The cylinder head bolts are torqued using the torque yield method, they should be examined
BEFORE reuse. If the threads are necked down, the
bolts should be replaced Fig. 30.
4. Necking can be checked by holding a scale or straight edge against the threads. If all the
threads do not contact the scale the bolt should be
replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 2008
Fig. 31 Cylinder Head Tightening Sequence
5. Tighten the cylinder head bolts 1 through 8 in the sequence shown in Fig. 31. Using the 4 step
torque turn method, tighten according to the
following values: ^
First-All to 61 Nm (45 ft. lbs.)
^ Second-All to 88 Nm (65 ft. lbs.)
^ Third-All (again) to 88 Nm (65 ft. lbs.)
^ Fourth + 1/4 turn Do not use a torque wrench for this step
NOTE: Bolt torque after 1/4 turn should be over 122 Nm (90 ft.lbs.). If not, replace the bolt.
6. Tighten head bolt number 9 Fig. 31 to 33 Nm (25 ft.lbs.) after head bolts 1 thorough 8 have been
tighten to specifications. 7. Inspect push rods and replace worn or bent rods.
Fig. 32 Rocker Arm Shaft Retainers
8. Install push rods, rocker arm and shaft assemblies with the stamped steel retainers in the four
positions, tighten to 28 Nm (250 in.lbs.) Fig. 32.
CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts.
9. Place new cylinder head cover gaskets in position and install cylinder head covers. Tighten to 12
Nm (105 in.lbs.).
INTAKE MANIFOLD SEALING
The intake manifold gasket is a one-piece stamped steel gasket with a sealer applied from the
manufacturer. This gasket has end seals incorporated with it.
WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury.
Handle with care.
1. Clean all surfaces of cylinder block and cylinder heads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 2009
Fig. 33 Intake Manifold Gasket Sealing
2. Place a drop (about 1/4 in. diameter) of Mopar Silicone Rubber Adhesive Sealant or equivalent,
onto each of the four manifold to cylinder head
gasket corners Fig. 33.
Fig. 34 Intake Manifold Gasket Retainers
3. Carefully install the intake manifold gasket Fig. 34. Torque end seal retainer screws to 12 Nm (105 in. lbs.).
Fig. 35 Intake Manifold Removal And Installation
4. Install intake manifold and 8 bolts and torque to 1 Nm (10 in.lbs.). Then tighten bolts to 22 Nm
(200 in.lbs.) in sequence shown in Fig. 35. Then
tighten again to 22 Nm (200 in.lbs.). After intake manifold is in place, inspect to make sure seals
are in place. Refer to Engine/Intake Manifold/Service and Repair to complete intake manifold
assembly. See: Intake Manifold/Service and Repair
5. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lb.) and nuts to 20 Nm (15 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 2010
6. Adjust spark plugs to specification and install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
REMOVAL
1. Raise vehicle on hoist. Remove right wheel and inner splash shield. 2. Remove drive belt.
3. Remove crankshaft damper.
4. Using Tool C-4991, or equivalent to remove oil seal. Be careful not to damage that crankshaft
seal surface of cover.
INSTALLATION
1. Install new seal by using Tool C-4992, or equivalent.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair > Page 2014
2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with
cover.
3. Install crankshaft pulley using plate L-4524, or equivalent. Thrust Bearing/washer and 5.9 inch
screw. 4. Install drive belt. 5. Install inner splash shield and wheel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair > Page 2015
Front Crankshaft Seal Installer C-4992
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket
> Component Information > Specifications
Intake Manifold Gasket: Specifications
Gasket Retaining Screws ....................................................................................................................
................................................. 12 Nm (105 inch lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket
> Component Information > Specifications > Page 2019
Intake Manifold Gasket: Service and Repair
GENERAL INFORMATION
The intake manifold gasket is a one-piece stamped steel gasket with a sealer applied from the
manufacturer. This gasket has end seals incorporated with it.
WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE
PERSONAL INJURY, HANDLE WITH CARE.
INSTALLATION
1. Clean all surfaces of cylinder block and cylinder heads.
2. Place a drop (about 1/4 inch diameter) of Mopar Silicone Rubber Adhesive Sealant or
equivalent, onto each of the four manifold to cylinder head
gasket corners.
3. Carefully install the intake manifold gasket. Torque end seal retainer screws to 12 Nm (105 inch
lbs.).
4. Install intake manifold and (8) bolts and torque to 1 Nm (10 inch lbs.). Then tighten bolts to 22
Nm (200 inch lbs.) in sequence shown. Then
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket
> Component Information > Specifications > Page 2020
tighten again to 22 Nm (200 inch lbs.). After intake manifold is in place, inspect to make sure seals
are in place.
5. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lbs.) and nuts to 20 Nm (15 ft. lbs.). 6.
Adjust spark plugs to specification and install the plugs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Gasket >
Component Information > Service and Repair
Timing Cover Gasket: Service and Repair
Timing Chain Cover Installation & Oil Seal Replacement
1. Ensure mating surfaces of chain case cover are clean and free of burrs. Crankshaft oil seal must
be removed to ensure correct oil pump
engagement.
Fig. 18 Crankshaft Oil Seal Removal
2. Remove crankshaft oil seal using crankshaft removal tool No. C-4991, or equivalent, as shown in
Fig. 18. Use caution not to damage crankshaft
seal surface of cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Gasket >
Component Information > Service and Repair > Page 2024
Fig. 19 Timing Case Cover Gasket & O-rings
3. Install a new cover gasket and new O-rings, Fig. 19. 4. Rotate crankshaft so oil pump drive flats
are vertical. 5. Position oil pump inner rotor so mating flats are in same position as crankshaft drive
flats, Fig. 19. 6. Install cover onto crankshaft. Ensure oil pump is correctly engaged on crankshaft
or severe damage may result. 7. Install chain case cover screws and tighten to specifications. 8.
Install crankshaft oil seal as follows:
a. Position seal into opening with seal spring towards inside of engine.
Fig. 20 Crankcase Oil Seal Installation
b. Install seal until flush with cover using seal crankshaft seal installing tool No. C-4992, or
equivalent, Fig. 20.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Gasket >
Component Information > Service and Repair > Page 2025
Fig. 21 Crankshaft Pulley Installation
9. Install crankshaft pulley using thrust bearing/washer plate tool No. L-4524, or equivalent and a
5.9 inch screw, Fig. 21. Tighten crankshaft pulley
bolt to specifications.
10. Install engine bracket, Fig. 14 and tighten attaching screws to specifications. 11. Install idler
pulley on engine bracket. 12. Install cam sensor. 13. Install A/C compressor mounting bracket, then
A/C compressor. 14. Install accessory drive belt. 15. Install right front inner splash shield, then
wheel and tire assembly. 16. Install oil pump pickup, oil pan and transaxle inspection cover, if
removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling
system. 20. Connect battery ground cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Description and Operation
Valve Guide Seal: Description and Operation
Viton valve stem seals provide valve sealing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Description and Operation > Page 2029
Valve Guide Seal: Service and Repair
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable.
3. Remove Air Cleaner Cover and hose assembly.
4. Remove upper Intake Manifold.
5. Remove cylinder head covers and spark plugs.
6. Remove connector wire from ignition coils.
7. Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the
number 1 piston is at Top Dead Center on the compression stroke.
8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be
disturbed and left on shaft.
9. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to
100 psi air pressure (620.5 to 689 kPa). This is to hold valves into place while servicing
components.
10. Using Tool C-4682, or equivalent compress valve spring and remove retainer valve locks and
valve spring.
11. The intake valve stem seals should be pushed firmly and squarely over the valve guide using
the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer
locks, compress the spring only enough to install the locks.
CAUTION: Do not pinch seal between retainer and top of valve guide.
12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6.
Make sure piston in cylinder is at Top Dead Center (TDC) on the valve spring that is being covered.
13. Remove spark plug adapter tool.
14. Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 inch
lbs.).
15. Install cylinder head covers tighten screws to 14 Nm (120 inch lbs.) and connector to ignition
coils.
16. Install Intake Manifold.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2036
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2037
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2038
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2039
Oil Pressure Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2040
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
.................................................... 54 Nm (40 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Sprocket <-->
[Crankshaft Gear/Sprocket] > Component Information > Description and Operation
Crankshaft Sprocket: Description and Operation
ACCESS PLUG
An Access plug is located in the right inner fender shield. Remove the plug and insert the proper
size socket, extension and ratchet, when crankshaft rotation is necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Specifications
Timing Chain: Specifications
Number of Links ..................................................................................................................................
.............................................................................. 64
Pitch .....................................................................................................................................................
................................................................. 0.375 inch
Width ...................................................................................................................................................
.................................................................. 0.750 inch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch
Timing Chain: Service and Repair Measuring Timing Chain Stretch
Fig. 16 Timing Chain Movement Inspection
1. Place a scale next to timing chain so chain movement can be measured. 2. Install a torque
wrench and socket over camshaft sprocket, then apply torque in direction of crankshaft rotation to
take up chain slack. Apply 30 ft.
lbs. of torque with cylinder heads installed or 15 ft. lbs. of torque with cylinder heads removed. With
torque applied to camshaft sprocket bolt, crankshaft should not move. It may be necessary to block
crankshaft to prevent rotation.
3. Holding a scale with dimension reading even with edge of a chain link, apply specified torque in
reverse direction and note amount of chain
movement, Fig. 16.
4. If timing chain movement exceeds 1/8 inch, replace chain.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch > Page 2053
Timing Chain: Service and Repair Timing Chain Replacement
Removal
TIMING COVER REMOVAL
1. Disconnect battery 2. Drain cooling system. Refer to Cooling System/Service and Repair for
procedure. 3. Support engine and remove right engine mount. 4. Raise vehicle on hoist. Drain
engine oil. 5. Remove oil pan and oil pump pick-up. It may be necessary to remove transmission
inspection cover. 6. Remove right wheel and inner splash shield. 7. Remove drive belt. Refer to
Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair for
procedure. 8. Remove A/C compressor and set aside. 9. Remove A/C compressor mounting
bracket.
Fig. 43 Removing Crankshaft Pulley
10. Remove crankshaft pulley Fig. 43. 11. Remove idler pulley from engine bracket.
Fig. 44 Engine Bracket (Typical)
12. Remove engine bracket Fig. 44.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch > Page 2054
Fig. 45 Timing Chain Case Cover
13. Remove cam sensor from chain case cover Fig. 45.
TIMING CHAIN REMOVAL
1. Remove camshaft sprocket attaching bolt, and remove timing chain with camshaft sprocket. 2.
Using a suitable puller remove the crankshaft sprocket. Be careful not to damage the crankshaft
surface.
Installation
TIMING CHAIN INSTALLATION
1. Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be
sure sprocket is seated into position. 2. Rotate crankshaft so the timing arrow is to the 12 o'clock
position. 3. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock
position. 4. Align the dark colored links with the dot on the camshaft sprocket, place timing chain
around crankshaft sprocket with the dark colored link lined
up with the dot on the sprocket and install camshaft sprocket into position.
Fig. 49 Alignment Of Timing Marks
5. Using straight edge to check alignment of timing marks Fig. 49. 6. Install camshaft bolt and
washer. Tighten to 54 Nm (40 ft. lbs.). 7. Rotate crankshaft 2 revolutions. Timing marks should line
up. If timing marks do not line up remove cam sprocket and realign.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch > Page 2055
Fig. 50 Camshaft Thrust Plate
8. Check camshaft endplay With new thrust plate the specification is 0.0127 to 0.304 mm (0.005 to
0.012 inches.). Old thrust plate specification is
0.31 mm (0.012 in.) maximum. If not within these limits install new thrust plate.
TIMING COVER INSTALLATION
1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure
correct oil pump engagement.
NOTE: Do not use a sealer on cover gasket.
Fig. 46 Timing Cover Rear Surface
2. Use a new cover gasket, O-rings Fig. 46. Adhere new gasket to timing cover, making sure that
the lower edge of the gasket flush to 0.5 mm (0.020
in.) passed the lower edge of the cover. Refer to oil pan sealing outlined in this section.
3. Rotate crankshaft so that the oil pump drive flats are vertical. 4. Position oil pump inner rotor so
the mating flats are in the same position as the crankshaft drive flats Fig. 46. 5. Install cover onto
crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may
result. 6. Install chain case cover screws and torque to 27 Nm (20 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch > Page 2056
Fig. 47 Installation Of Crankshaft Front Oil Seal
7. Install crankshaft oil seal Fig. 47.
Fig. 48 Installation Of Crankshaft Pulley
8. Install crankshaft pulley Fig. 48. 9. Install engine bracket Fig. 44 torque screws to 54 Nm (40
ft.lbs.).
10. Install idler pulley on engine bracket. 11. Install cam sensor. 12. Install A/C compressor
mounting bracket. 13. Install A/C compressor. 14. Install drive belt. Refer to Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive Belt/Service and Repair for installation procedure. 15.
Install inner splash shield and wheel. 16. Install oil pump pick-up and oil pan and transmission
inspection cover if removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19.
Fill cooling system. Refer to Cooling System/Service and Repair for procedure. 20. Connect battery
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Fundamentals and Basics > General Information
Timing Chain: Fundamentals and Basics General Information
TIMING CHAIN GENERAL INFORMATION
PURPOSE
The timing chain synchronizes (times) the opening and closing of the intake and exhaust valves
with the movement/stroke 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 chain 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 twice as large
as the crankshaft. This allows the smaller crankshaft to complete two revolutions while the larger
camshaft completes only one revolution.
FIRST INDICATIONS OF A BROKEN TIMING CHAIN
- The engine will immediately die or fail to start.
- When attempting to restart the engine, the cranking speed (rpm) will be unusually fast.
- 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 chain brakes the camshaft quits rotating. 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 THE TIMING CHAIN IS BROKEN
- Remove oil filler cap and check if the valve train or rocker arms are visible. If the timing chain is
broken there will be no valve train movement while cranking the engine.
- Perform a compression check. If the timing chain is broken no cylinder will develop compression.
NOTE: Because this engine uses a distributorless ignition system and a crankshaft sensor the
engine may still have ignition spark with a broken timing chain.
OTHER RELATED PROBLEMS
The Timing Chain has Jumped Teeth If the chain is excessively worn or missing teeth it is possible for the chain to jump teeth on the
crankshaft.
- A chain which is off by just one tooth will cause an engine to run very poorly or not run at all.
- A chain which is off by more than one tooth will generally prevent the engine from starting.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Fundamentals and Basics > General Information > Page 2059
Timing Chain: Fundamentals and Basics Installation and Removal Hints and Tips
TIMING CHAIN REPLACEMENT HINTS AND TIPS
- Always replace both the timing chain and sprocket as a combined unit. A worn timing chain will not properly fit the teeth of a new sprocket and will result in a premature
failure.
- A new timing chain will rapidly wear away the teeth of an old sprocket.
- Check ignition timing before (if possible) and after the procedure. This will help you verify the job
was done properly. A timing chain which is off just one tooth will significantly alter the ignition
timing.
NOTE: Since the drive belt will need to be removed during this procedure, it is important to note
any related deficiencies prior to starting the procedure. Inspect the water pump for signs of leakage and inspect the pulley for any looseness or wobble. If
any wobble is detected the water pump should be replaced.
- Inspect the drive belts and replace if necessary.
- Inspect the drive belt idler/tensioner pulleys for looseness and wobble. Replace any pulley which
does not spin freely or has any wobble.
- Rotate the engine to number 1 Top Dead Center prior to removing the timing chain.
- Oil pan removal is required to remove the timing cover. Bolts from the oil pan extend through the
bottom of the timing cover. Removing the bolts and loosening the remaining pan bolts to remove
the timing cover will tend to cause oil leakage from the pan gasket.
NOTE: To prevent leakage, when the oil pan is removed or the bolts are loosened, the gasket
should always be replaced.
- When tightening the oil pan bolts always use a torque wrench. Correct sealing requires the gasket
to be evenly torqued across its entire sealing surface.
- Do not turn the crankshaft or camshaft with the pulleys off. Using slip joint pliers or pipe wrenches
to turn the crankshaft will damage the surface and affect the press fit of the pulley.
- Silicone sealant should be used very sparingly. Excessive sealant which squeezes out on the
inside of the gasket can accumulate and restrict the oil pump pickup screen or the coolant heater
core.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
M8x1.25 Bolts ......................................................................................................................................
.................................................... 27 Nm (20 ft. lbs.) M10x1.5 Bolts ...................................................
....................................................................................................................................... 54 Nm (40 ft.
lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2063
Timing Cover: Service and Repair
Fig. 6 Crankshaft pulley removal
Fig. 7 Engine bracket
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2064
Fig. 8 Timing case cover
REMOVAL
1. Disconnect battery ground cable. 2. Drain cooling system. 3. Support engine, then remove right
engine mount. 4. Raise and support vehicle, then drain engine oil. 5. Remove oil pan and oil pump
pick up. It may be necessary to remove transaxle inspection cover. 6. Remove accessory drive belt
as follows:
a. Remove right front wheel and tire assembly, then the inner splash shield.
b. Release belt tension by rotating tensioner clockwise, then remove accessory drive belt.
7. Remove A/C compressor and position aside. 8. Remove A/C compressor mounting bracket. 9.
Using a suitable puller, remove crankshaft pulley as shown, Fig. 6. Pull from inner hub area only.
10. Remove idler pulley from engine bracket, then the engine bracket, Fig. 7. 11. Remove cam
sensor from chain case cover, then the chain case cover, Fig. 8.
REPLACEMENT
1. Ensure mating surfaces of chain case cover are clean and free of burrs. Crankshaft oil seal must
be removed to ensure correct oil pump
engagement.
Fig. 11 Crankshaft oil seal removal
2. Remove crankshaft oil seal using crankshaft removal tool No. C-4991 or equivalent, as shown in
Fig. 11. Use caution not to damage crankshaft
seal surface of cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2065
Fig. 12 Timing case cover gasket & O-rings
3. Install a new cover gasket and new O-rings, Fig. 12. 4. Rotate crankshaft so oil pump drive flats
are vertical. 5. Position oil pump inner rotor so mating flats are in same position as crankshaft drive
flats, Fig. 12. 6. Install cover onto crankshaft. Ensure oil pump is correctly engaged on crankshaft
or severe damage may result. 7. Install chain case cover screws and tighten to specifications. 8.
Install crankshaft oil seal as follows:
a. Position seal into opening with seal spring towards inside of engine.
Fig. 13 Crankcase oil seal installation
b. Install seal until flush with cover using seal crankshaft seal installing tool No. C-4992 or
equivalent, Fig. 13.
Fig. 14 Crankshaft pulley installation
9. Install crankshaft pulley using thrust bearing/washer plate tool No. L-4524 or equivalent and a
5.9 inch screw, Fig. 14. Tighten crankshaft pulley
bolt to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2066
Fig. 7 Engine bracket
10. Install engine bracket, Fig. 7 and tighten attaching screws to specifications. 11. Install idler
pulley on engine bracket. 12. Install cam sensor. 13. Install A/C compressor mounting bracket, then
the A/C compressor. 14. Install accessory drive belt. 15. Install right front inner splash shield, then
the wheel and tire assembly. 16. Install oil pump pickup, oil pan and transaxle inspection cover, if
removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling
system. 20. Connect battery ground cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Specifications > Page 2075
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through
Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable,
inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform
minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES
MINIMUM AIRFLOW TEST IDLE SPEED
ODOMETER READING IDLE SPEED
Less than 1000 miles 525-875 RPM
More than 1000 miles 575-875 RPM
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 2079
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 (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Fuel Pressure Release Procedure - Typical
WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even
when the engine is OFF.
1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3.
Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose,
tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this
hose to
the fuel rail service port. Fuel pressure should bleed off into container.
5. Perform necessary fuel system service procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Timing Marks and Indicators > System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2102
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2103
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: >
080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: >
080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2109
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: >
080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2110
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Page 2111
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Page 2112
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
Purpose
Transfer electrical current from the distributor to individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2115
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables
must be released from inside the distributor cap.
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic
converter. Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an
open circuit or other damage.
INSPECTION
Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully
seated, and the nipples and spark plug covers should be in good condition.
Covers should fit tightly on the coil, distributor cap towers and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
RESISTANCE TEST
Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
Remove cable from spark plug.
Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables
must be removed from the spark plugs.
Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside
the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance
shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower
and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all
spark plug cables in same manner.
To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not
remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove
the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the
cable. Also, check for a loose connection at the tower or for a faulty coil.
Inspect coil tower for cracks or carbon tracking.
Secondary Ignition Cable Resistance Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten
minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
SPARK PLUG CABLES
1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not
remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the
ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure
probes make good contact.
Resistance should be within tolerance.
4. If the resistance is not within tolerance, remove cable at cap tower and check the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2116
5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in
same manner.
COIL TO DISTRIBUTOR HIGH TENSION CABLE
1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the
cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of
cable. 4. If resistance is not within tolerance, replace the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
NOTE: 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.
Spark Plug Gap ...................................................................................................................................
............................... 1.2 to 1.3 mm (0.048 to 0.053 in)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap Specifications > Page 2121
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
....................................................... 28 Nm (20 ft-lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2122
Spark Plug: Description and Operation
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for
spark plug diagnosis.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2125
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2126
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2127
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2128
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2129
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2130
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2131
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
PROCEDURE
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Page 2132
Spark Plug: Adjustments
Setting Spark Plug Electrode Gap
Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the
ground -- center electrode.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Service and Repair > Replacement Notes
Spark Plug: Service and Repair Replacement Notes
TIP: Always keep plugs in the order they were removed. Any plug that looks different from other
plugs indicates a problem in that cylinder.
NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and
Inspection/Procedures
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Service and Repair > Replacement Notes > Page 2135
Spark Plug: Service and Repair Removal and Installation
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
REMOVAL
1. Spray compressed air around spark plug to prevent foreign material from entering combustion
chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back
in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR:
- Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION
1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Cylinder Compression Pressure 100 psi
NOTE: No more than 25% variance between cylinders.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2139
Compression Check: Service Precautions
COMPRESSION TESTING
When performing a compression test, remove the fuel pump relay fuse and disconnect power to
the ignition. This will stop fuel flow to the injectors and prevent engine from starting.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2140
Compression Check: Testing and Inspection
PROCEDURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. 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. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For
Direct Ignition System (DIS) disconnect the coil connector.
5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage.
Record this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689
kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem
in the cylinder in question. The recommended compression pressures are to be used only as a
guide to diagnosing engine problems. An engine should not be disassembled to determine the
cause of low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16.
Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test
vehicle as a final test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Adjustments
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters, no adjustment is necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 2148
- 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 2149
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 2150
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 2151
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair > Removal
Water Pump: Service and Repair Removal
Fig. 6 Water Pump
REMOVE
1. Drain Cooling System. 2. Remove Accessory Drive Belt. 3. Remove right front lower fender
shield. 4. Remove pump pulley bolts and remove pulley. 5. Remove pump mounting screws
Remove pump.
Fig. 7 Water Pump Body
6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and
chain case cover. Take care not to scratch or gouge sealing surface.
INSPECT
NOTE: Replace the water pump if it has any of the following defects.
1. Damage or cracks on the pump body. 2. Coolant leaks; if the seal is leaking, evident by traces of
coolant leaks from vent hole. 3. Loose or rough turning bearing. 4. Impeller - rubs either the pump
body or chain case cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair > Removal > Page 2154
Water Pump: Service and Repair Installation
Fig. 7 Water Pump Body
Fig. 6 Water Pump
INSTALL
1. Install new O-ring in O-ring groove. 2. Install pump to chain case cover. Torque screws to 12 Nm
(105 in.lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on
pump. Install screws and torque to 30 Nm (250 in.lbs.). 5. Install drive belt. See Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive Belt/Service and Repair.
See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair
6. Install right front lower fender shield. 7. Refill Cooling System. See Cooling System/Service and
Repair.
See: Cooling System/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair > Page 2155
Water Pump: Tools and Equipment
RECOMMENDED TOOLS
- Drip pan - For draining coolant.
- Torque Wrenches (0-30 in lbs).
- Full set of Metric sockets and wrenches.
- Fender covers.
OPTIONAL
- Radiator hose removal tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair > Page 2156
- Cooling system pressure tester.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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.
NOTE: A fender cover folded over the radiator will prevent accidental damage to the radiator. The
radiator can be easily damaged should a wrench slip off of a bolt while working on the water pump.
Coolant Drip Pan
Pre-position a drip pan under the vehicle to prevent any incidental spills.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2159
Water Pump: Fundamentals and Basics Removal Tips and Hints
WATER PUMP REMOVAL NOTES, WARNINGS, 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 and 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2160
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2161
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2162
Water Pump: Fundamentals and Basics Installation Tips and Hints
WATER PUMP INSTALLATION NOTES
- Compare the old pump to the new pump and verify: Shaft lengths match exactly.
- Retaining bolt holes match exactly.
- Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as
necessary.
- 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.
- 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2163
Water Pump: Fundamentals and Basics Recommended Parts
RECOMMENDED PARTS
- New water pump O-ring.
- Engine Coolant:
NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and
water.
OPTIONAL, PENDING INSPECTION
- Radiator hoses.
- Drive belt.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Engine - Coolant Recommendations > Page 2169
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Page 2170
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Motor: >
07-06-98 > Nov > 98 > Cooling Module Fan - Vibrates/Comes Loose
Radiator Cooling Fan Motor: Customer Interest Cooling Module Fan - Vibrates/Comes Loose
NO: 07-06-98
GROUP: Cooling
DATE: Nov. 20, 1998
SUBJECT: Cooling Module Fan Nut
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(International Market)
DISCUSSION:
Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling
module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and
the engine may overheat.
A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to
address this condition and should be used for repair any time this condition is experienced and the
fan blade is not damaged.
The cooling fan blade and motor were balanced as an assembly at the time of manufacture and
must be properly oriented to minimize vibration. The cooling fan blade can be installed on the
cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates
excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft
180 degrees from the first installation position.
The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor: > 07-06-98 > Nov > 98 > Cooling Module Fan - Vibrates/Comes Loose
Radiator Cooling Fan Motor: All Technical Service Bulletins Cooling Module Fan - Vibrates/Comes
Loose
NO: 07-06-98
GROUP: Cooling
DATE: Nov. 20, 1998
SUBJECT: Cooling Module Fan Nut
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(International Market)
DISCUSSION:
Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling
module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and
the engine may overheat.
A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to
address this condition and should be used for repair any time this condition is experienced and the
fan blade is not damaged.
The cooling fan blade and motor were balanced as an assembly at the time of manufacture and
must be properly oriented to minimize vibration. The cooling fan blade can be installed on the
cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates
excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft
180 degrees from the first installation position.
The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2187
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2188
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2189
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190
Radiator Cooling Fan Motor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191
Radiator Cooling Fan Motor: Electrical Diagrams
Air Conditioning System (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192
Air Conditioning System (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193
Air Conditioning System (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2194
Air Conditioning System (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2195
Radiator Fan System With Heater
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196
Heater System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 2197
Radiator Cooling Fan Motor: Description and Operation
Fig. 1 Electric Cooling Fan Module
Fig. 2 Electric Cooling Fan Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 2198
Fig. 3 Electric Cooling Fan Module
ELECTRIC COOLING FANS, DESCRIPTION
The electric cooling fan, is controlled by a fan switch which is located on the radiator or engine, or
is activated by an on-board computer. The switch on the radiator will engage the fan when coolant
temperature reaches 200°F. The on-board computer uses two thermistor sensors, one of which is
for the cooling system fan, to detect coolant temperature.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 2199
Radiator Cooling Fan Motor: Testing and Inspection
ELECTRIC FAN MOTOR
1. Disconnect fan motor electrical connector. 2. Connect jumper wire to positive side of fan motor
connector. 3. Fan should operate properly; if not, replace fan motor. 4. If fan is noticeably
overheated, system voltage may be too high. Inspect charging system as necessary.
Refer to Cooling System / Testing and Inspection / Procedures / Diagnostic Charts for further
Diagnosis.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 2200
Radiator Cooling Fan Motor: Service and Repair
Fig. 1 Electric Cooling Fan Module
Fig. 2 Electric Cooling Fan Module
COMPONENT REPLACEMENT, COOLING FAN
^ Disconnect battery ground cable and electrical connector from fan motor.
^ Remove shroud clips and support bolts, nuts and washers.
^ Remove fan, motor and shroud or support as an assembly from radiator support.
^ Remove fan from motor shaft by supporting assembly on bench, remove retaining clip and sliding
fan away.
^ Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations
Radiator Fan Relay: Locations
Radiator Fan Relay is located in the Power Distribution Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2204
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions
Radiator Fan Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2208
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2209
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2210
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2211
Radiator Fan Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2212
Radiator Fan Relay: Electrical Diagrams
Air Conditioning System (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2213
Air Conditioning System (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2214
Air Conditioning System (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2215
Air Conditioning System (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2216
Radiator Fan System With Heater
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay
<--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions >
Page 2217
Heater System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > Customer Interest for Fan Blade: > 07-06-98 > Nov > 98 > Cooling
Module Fan - Vibrates/Comes Loose
Fan Blade: Customer Interest Cooling Module Fan - Vibrates/Comes Loose
NO: 07-06-98
GROUP: Cooling
DATE: Nov. 20, 1998
SUBJECT: Cooling Module Fan Nut
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(International Market)
DISCUSSION:
Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling
module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and
the engine may overheat.
A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to
address this condition and should be used for repair any time this condition is experienced and the
fan blade is not damaged.
The cooling fan blade and motor were balanced as an assembly at the time of manufacture and
must be properly oriented to minimize vibration. The cooling fan blade can be installed on the
cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates
excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft
180 degrees from the first installation position.
The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 07-06-98 > Nov > 98
> Cooling Module Fan - Vibrates/Comes Loose
Fan Blade: All Technical Service Bulletins Cooling Module Fan - Vibrates/Comes Loose
NO: 07-06-98
GROUP: Cooling
DATE: Nov. 20, 1998
SUBJECT: Cooling Module Fan Nut
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(International Market)
DISCUSSION:
Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling
module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and
the engine may overheat.
A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to
address this condition and should be used for repair any time this condition is experienced and the
fan blade is not damaged.
The cooling fan blade and motor were balanced as an assembly at the time of manufacture and
must be properly oriented to minimize vibration. The cooling fan blade can be installed on the
cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates
excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft
180 degrees from the first installation position.
The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical
Specifications
Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications
NOTE: For information on how this type of sensor operates SEE, Powertrain
Management/Computers and Control Systems/Coolant Temperature Sensor/Description and
Operation.
NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM).
COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
-20° F ...................................................................................................................................................
....................................... 4.70 V
-10° F ...................................................................................................................................................
....................................... 4.57 V
0° F ......................................................................................................................................................
...................................... 4.45 V
10° F ....................................................................................................................................................
....................................... 4.30 V
20° F ....................................................................................................................................................
....................................... 4.10 V
30° F ....................................................................................................................................................
....................................... 3.90 V
40° F ....................................................................................................................................................
....................................... 3.60 V
50° F ....................................................................................................................................................
....................................... 3.30 V
60° F ....................................................................................................................................................
....................................... 3.00 V
70° F ....................................................................................................................................................
....................................... 2.75 V
80° F ....................................................................................................................................................
....................................... 2.44 V
90° F ....................................................................................................................................................
....................................... 2.15 V
100° F ..................................................................................................................................................
........................................ 1.83 V
110° F ..................................................................................................................................................
........................................ 1.57 V
120° F ..................................................................................................................................................
........................................ 1.25 V
HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
110° F ..................................................................................................................................................
........................................ 4.20 V
120° F ..................................................................................................................................................
........................................ 4.00 V
130° F ..................................................................................................................................................
........................................ 3.77 V
140° F ..................................................................................................................................................
........................................ 3.60 V
150° F ..................................................................................................................................................
........................................ 3.40 V
160° F ..................................................................................................................................................
........................................ 3.20 V
170° F ..................................................................................................................................................
........................................ 3.02 V
180° F ..................................................................................................................................................
........................................ 2.80 V
190° F ..................................................................................................................................................
........................................ 2.60 V
200° F ..................................................................................................................................................
........................................ 2.40 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical
Specifications > Page 2236
210° F ..................................................................................................................................................
........................................ 2.20 V
220° F ..................................................................................................................................................
........................................ 2.00 V
230° F ..................................................................................................................................................
........................................ 1.80 V
240° F ..................................................................................................................................................
........................................ 1.62 V
250° F ..................................................................................................................................................
........................................ 1.45 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical
Specifications > Page 2237
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
2238
Coolant Temperature Sensor/Switch (For Computer): Locations
Ignition Coil And Coolant Temperature Sensor Location
Sensor mounted under ignition coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram
Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2241
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2242
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2243
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2244
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2245
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2246
Coolant Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2247
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
LOCATION
The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the
thermostat housing.
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2248
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Coolant Temperature Sensor Resistance Test
1. With key off, disconnect connector from coolant temperature sensor.
2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows;
- 700 to 1,000 Ohms at approximately 200°F (operating temperature).
- 7,000 to 13,000 ohms at approximately 70°F, (room temperature).
3. If resistance is not within specifications, replace sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2249
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Ignition Coil And Coolant Temperature Sensor Location
REMOVAL
1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical
connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant
temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6.
Remove sensor from engine.
INSTALLATION
1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor.
3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12
Nm (105 in lbs) torque. 5. Connect electrical connector to coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2255
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2256
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2257
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2258
Temperature Sensor (Gauge): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2259
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 2260
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.
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and
Inspection
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core
Heater Core: Service and Repair Front Heater Core
1. Set parking brake and disconnect battery ground cable. 2. Discharge and recover system
refrigerant. 3. Disconnect all engine compartment heater and air conditioning lines and vacuum
hoses. 4. Drain engine coolant and plug lines. 5. Remove instrument panel as described in
Instrument Panel/Service and Repair/Dash Panel Replacement. 6. Disconnect air conditioning
hanger strap and temporarily reposition. 7. Remove rubber condensate drain tube and four
mounting nuts in engine compartment.
Fig. 10 A/C & Heater Assembly
8. Pull heater/air conditioning assembly to rear until unit studs clear dash panel, then drop unit
down and remove from vehicle. 9. Place heater/air conditioning assembly on suitable workbench,
then remove screw at vacuum harness and feed harness through hole in cover.
10. Remove thirteen screws from top cover, then remove top cover. 11. Remove screw from heater
core tube retaining bracket, then lift heater core out of unit. 12. Remove evaporator core from unit.
13. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core > Page 2265
Heater Core: Service and Repair Rear Heater Core
REMOVE AND INSTALL
1. Drain the engine coolant system.
Rear Heater Plumbing
2. Disconnect heater tubing from the underbody heater lines to the rear unit. 3. Remove the lower
left quarter trim panel. 4. Remove fan A/C distribution duct. 5. Remove heater-unit cover. 6.
Carefully pull the heater core and heater tubes straight out of the unit. 7. Raise the heater core to
drain residual coolant from the core. 8. Disconnect two heater hose clamps that attach plumbing to
the heater core tube. 9. To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hoses
Heater Hose: Service and Repair Heater Hoses
Review Safety Precautions and Warnings the in General Information section before proceeding
with this operation.
1. Drain engine cooling system.
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peal off heater hose. This method will require heater hose replacement.
To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hoses > Page 2271
Heater Hose: Service and Repair Underbody Plumbing
WARNING: THE ENGINE COOLING SYSTEM MUST BE RELIEVED OF ALL PRESSURE.
1. Drain the engine cooling system.
2. In the engine compartment, and disconnect two auxiliary rear heater hoses from the (front)
heater hose tee fittings.
3. Hoist the vehicle. Disconnect two push-together couplings from the auxiliary rear heater core
tubes protruding through the floor pan.
4. Remove four bolts and one pal nut holding the plumbing to the floor pan and lower the plumbing
from the vehicle.
To Install, Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Service and Repair
Radiator: Service and Repair
1. Disconnect battery ground cable, then drain cooling system. 2. Remove hose clamps and hoses
from radiator, then remove coolant reserve tank tube. 3. Remove automatic transmission hoses
and auxiliary oil cooler, if equipped. 4. Disconnect fan motor electrical connector, then remove fan
and support assembly. 5. Remove upper shroud fasteners, then lift shroud up and out of bottom
attaching clips. 6. Remove front grille, then remove air conditioning condenser fasteners and
separate condenser from radiator. 7. Remove upper radiator mounting screws, then disconnect
engine block heater wire, if equipped. 8. Lift radiator from engine compartment being careful not to
damage cooling fins or water tubes. 9. Reverse procedure to install. Tighten to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations
Radiator Fan Relay: Locations
Radiator Fan Relay is located in the Power Distribution Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2279
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2280
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions
Radiator Fan Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2283
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2284
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2285
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2286
Radiator Fan Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2287
Radiator Fan Relay: Electrical Diagrams
Air Conditioning System (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2288
Air Conditioning System (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2289
Air Conditioning System (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2290
Air Conditioning System (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2291
Radiator Fan System With Heater
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information
and Instructions > Page 2292
Heater System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications
Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications
NOTE: For information on how this type of sensor operates SEE, Powertrain
Management/Computers and Control Systems/Coolant Temperature Sensor/Description and
Operation.
NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM).
COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
-20° F ...................................................................................................................................................
....................................... 4.70 V
-10° F ...................................................................................................................................................
....................................... 4.57 V
0° F ......................................................................................................................................................
...................................... 4.45 V
10° F ....................................................................................................................................................
....................................... 4.30 V
20° F ....................................................................................................................................................
....................................... 4.10 V
30° F ....................................................................................................................................................
....................................... 3.90 V
40° F ....................................................................................................................................................
....................................... 3.60 V
50° F ....................................................................................................................................................
....................................... 3.30 V
60° F ....................................................................................................................................................
....................................... 3.00 V
70° F ....................................................................................................................................................
....................................... 2.75 V
80° F ....................................................................................................................................................
....................................... 2.44 V
90° F ....................................................................................................................................................
....................................... 2.15 V
100° F ..................................................................................................................................................
........................................ 1.83 V
110° F ..................................................................................................................................................
........................................ 1.57 V
120° F ..................................................................................................................................................
........................................ 1.25 V
HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
110° F ..................................................................................................................................................
........................................ 4.20 V
120° F ..................................................................................................................................................
........................................ 4.00 V
130° F ..................................................................................................................................................
........................................ 3.77 V
140° F ..................................................................................................................................................
........................................ 3.60 V
150° F ..................................................................................................................................................
........................................ 3.40 V
160° F ..................................................................................................................................................
........................................ 3.20 V
170° F ..................................................................................................................................................
........................................ 3.02 V
180° F ..................................................................................................................................................
........................................ 2.80 V
190° F ..................................................................................................................................................
........................................ 2.60 V
200° F ..................................................................................................................................................
........................................ 2.40 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 2299
210° F ..................................................................................................................................................
........................................ 2.20 V
220° F ..................................................................................................................................................
........................................ 2.00 V
230° F ..................................................................................................................................................
........................................ 1.80 V
240° F ..................................................................................................................................................
........................................ 1.62 V
250° F ..................................................................................................................................................
........................................ 1.45 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 2300
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 2301
Coolant Temperature Sensor/Switch (For Computer): Locations
Ignition Coil And Coolant Temperature Sensor Location
Sensor mounted under ignition coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2304
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2305
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2306
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2307
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2308
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2309
Coolant Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Page 2310
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
LOCATION
The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the
thermostat housing.
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Page 2311
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Coolant Temperature Sensor Resistance Test
1. With key off, disconnect connector from coolant temperature sensor.
2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows;
- 700 to 1,000 Ohms at approximately 200°F (operating temperature).
- 7,000 to 13,000 ohms at approximately 70°F, (room temperature).
3. If resistance is not within specifications, replace sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Page 2312
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Ignition Coil And Coolant Temperature Sensor Location
REMOVAL
1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical
connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant
temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6.
Remove sensor from engine.
INSTALLATION
1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor.
3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12
Nm (105 in lbs) torque. 5. Connect electrical connector to coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2318
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2319
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2320
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2321
Temperature Sensor (Gauge): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2322
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
2323
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.
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and
Inspection
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Service and Repair
Thermostat: Service and Repair
WARNING: Do not remove pressure cap with the system hot and under pressure. Serious burns
from coolant can occur.
REMOVAL
1. With a suitable container placed below draincock, drain engine coolant below level of thermostat.
2. Remove thermostat housing bolts, then the housing. 3. Remove thermostat and gasket, then
discard gasket and clean mating surfaces.
NOTE: The thermostat is in a water box, formed in the drive belt side of the intake manifold.
INSTALLATION
Place a new gasket (dipped in water) on the water box surface, center thermostat into opening in
the intake manifold. Place housing over gasket and thermostat, making sure thermostat is in recess
provided. Bolt housing to intake manifold, tighten bolts to 28 Nm (250 in.lbs.). Refill cooling system.
See Cooling System/Service and Repair. See: Service and Repair
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 2331
- 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 2332
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 2333
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 2334
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Removal
Water Pump: Service and Repair Removal
Fig. 6 Water Pump
REMOVE
1. Drain Cooling System. 2. Remove Accessory Drive Belt. 3. Remove right front lower fender
shield. 4. Remove pump pulley bolts and remove pulley. 5. Remove pump mounting screws
Remove pump.
Fig. 7 Water Pump Body
6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and
chain case cover. Take care not to scratch or gouge sealing surface.
INSPECT
NOTE: Replace the water pump if it has any of the following defects.
1. Damage or cracks on the pump body. 2. Coolant leaks; if the seal is leaking, evident by traces of
coolant leaks from vent hole. 3. Loose or rough turning bearing. 4. Impeller - rubs either the pump
body or chain case cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Removal > Page 2337
Water Pump: Service and Repair Installation
Fig. 7 Water Pump Body
Fig. 6 Water Pump
INSTALL
1. Install new O-ring in O-ring groove. 2. Install pump to chain case cover. Torque screws to 12 Nm
(105 in.lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on
pump. Install screws and torque to 30 Nm (250 in.lbs.). 5. Install drive belt. See Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive Belt/Service and Repair.
See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair
6. Install right front lower fender shield. 7. Refill Cooling System. See Cooling System/Service and
Repair.
See: Service and Repair
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Page 2338
Water Pump: Tools and Equipment
RECOMMENDED TOOLS
- Drip pan - For draining coolant.
- Torque Wrenches (0-30 in lbs).
- Full set of Metric sockets and wrenches.
- Fender covers.
OPTIONAL
- Radiator hose removal tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Page 2339
- Cooling system pressure tester.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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.
NOTE: A fender cover folded over the radiator will prevent accidental damage to the radiator. The
radiator can be easily damaged should a wrench slip off of a bolt while working on the water pump.
Coolant Drip Pan
Pre-position a drip pan under the vehicle to prevent any incidental spills.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2342
Water Pump: Fundamentals and Basics Removal Tips and Hints
WATER PUMP REMOVAL NOTES, WARNINGS, 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 and 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2343
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2344
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2345
Water Pump: Fundamentals and Basics Installation Tips and Hints
WATER PUMP INSTALLATION NOTES
- Compare the old pump to the new pump and verify: Shaft lengths match exactly.
- Retaining bolt holes match exactly.
- Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as
necessary.
- 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.
- 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 2346
Water Pump: Fundamentals and Basics Recommended Parts
RECOMMENDED PARTS
- New water pump O-ring.
- Engine Coolant:
NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and
water.
OPTIONAL, PENDING INSPECTION
- Radiator hoses.
- Drive belt.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 110396 > Jun > 96 > Catalytic
Converter - Excessive Sulfur Odor
Catalytic Converter: Customer Interest Catalytic Converter - Excessive Sulfur Odor
NO: 11-03-96
GROUP: Exhaust
EFFECTIVE DATE: June 17, 1996
SUBJECT: Excessive Sulphur Odor
MODELS:
1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994
(AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY.
SYMPTOM/CONDITION:
New catalytic converters are now available to address customer complaints of excessive hydrogen
sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts
were specially manufactured with a revised internal coating which minimizes sulphur odor.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves the replacement of the catalytic converter with a revised part.
Replace the catalytic converter following the repair procedures given in group 11 of the appropriate
service manual.
POLICY: Reimbursable within the provisions of the warranty,
TIME ALLOWANCE:
Labor Operation No: 11-50-01-91 0.7 Hrs.
FAILURE CODE: P8-New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 110396 > Jun > 96 >
Catalytic Converter - Excessive Sulfur Odor
Catalytic Converter: All Technical Service Bulletins Catalytic Converter - Excessive Sulfur Odor
NO: 11-03-96
GROUP: Exhaust
EFFECTIVE DATE: June 17, 1996
SUBJECT: Excessive Sulphur Odor
MODELS:
1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994
(AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY.
SYMPTOM/CONDITION:
New catalytic converters are now available to address customer complaints of excessive hydrogen
sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts
were specially manufactured with a revised internal coating which minimizes sulphur odor.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves the replacement of the catalytic converter with a revised part.
Replace the catalytic converter following the repair procedures given in group 11 of the appropriate
service manual.
POLICY: Reimbursable within the provisions of the warranty,
TIME ALLOWANCE:
Labor Operation No: 11-50-01-91 0.7 Hrs.
FAILURE CODE: P8-New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 2361
Exhaust System - FWD Minivans
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 2362
Catalytic Converter: Description and Operation
Three Way Catalyst (TWC)
PURPOSE
Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and
Oxides of Nitrogen (NOx)), by up to 90%.
OPERATION
Oxidation Reaction
As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation
(burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor
(H2O) and Carbon Dioxide (CO2).
This process no effect on NOx emissions.
Reduction Reaction
The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal
of oxygen), reaction.
OPERATING ENVIRONMENT
A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only
be achieved in a properly functioning feedback system with oxygen sensor.
The ideal converter operating temperature, for maximum emission reduction and long service life
is, 400°C - 800°C (750°F - 1500°F).
Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede
1400°C (2500°F), which can melt substrate material.
CONSTRUCTION
Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately
2 grams of platinum and rhodium).
CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material,
reducing or eliminating catalyst activity.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 2363
Catalytic Converter: Service and Repair
Exhaust System - FWD Minivans
REMOVAL
1. Remove clamp holding muffler to converter.
2. Remove muffler from converter (it may be necessary to heat the pipe connection). 3. Remove
clamp securing converter to header pipe. 4. Remove converter from header pipe (it may be
necessary to heat the pipe connection).
INSTALLATION
1. Install converter to header pipe with a new clamp.
2. Reposition rear exhaust pipe hanger. 3. Install muffler to converter with a new clamp. 4. Start the
engine and inspect for exhaust leaks
NOTE: Replace any missing or damaged heat shields.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications
Exhaust Manifold: Specifications
TORQUE SPECIFICATIONS
Heat Shield Mounting Screws .............................................................................................................
................................................... 8 Nm ( 75 in.lbs.) Heat Shield Mounting Nuts .................................
................................................................................................................................. 5 Nm ( 45
in.lbs.). Insulator Mounting Bolts .........................................................................................................
.......................................................... 17 Nm (150 in.lbs.) U-Bolt Nuts & Uni-Clamp Nut
..........................................................................................................................................................
28 Nm (250 in.lbs.) Exhaust Flange Nuts ............................................................................................
.............................................................................. 28 Nm (250 in.lbs.) Exhaust Manifold Mounting
Stud
...................................................................................................................................................... 23
Nm (200 in.lbs.) Exhaust Manifold Mounting Screws
.................................................................................................................................................. 23 Nm
(200 in.lbs.) Exhaust Manifold Crossover Bolts
....................................................................................................................................................... 33
Nm (25 ft.lbs.) Exhaust Manifold Crossover Nuts
........................................................................................................................................................ 33
Nm (25 ft.lbs.) Heat Shield Mounting Screws
............................................................................................................................................................
23 Nm (200 in.lbs.)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications > Page 2367
Exhaust Manifold: Service and Repair
REMOVAL
1. Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at articulated
joint.
Fig. 16 EGR Tube, Heated Oxygen Sensor And Alternator/Power Steering Strut
2. Separate EGR tube from rear manifold and disconnect Heated Oxygen Sensor lead wire. 3.
Remove Alternator/Power Steering Support Strut. 4. Remove bolts attaching cross-over pipe to
manifold. 5. Remove bolts attaching rear manifold to cylinder head and remove manifold.
Fig. 17 Heat Shield
6. Lower vehicle and remove screws attaching front heat shield to front manifold.
Fig. 18 Crossover Pipe
7. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to
cylinder head. Remove assemblies.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications > Page 2368
Fig. 19 Check Exhaust Manifold Mounting Surface
INSPECTION
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
1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 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 33 Nm (25 ft.lbs.) and connect oxygen sensor lead. 4.
Reinstall EGR Tube and Alternator/Power Steering Strut. 5. Install front exhaust manifold and
attach exhaust crossover. 6. Install front manifold heat shield and tighten attaching screws to 23
Nm (200 in.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks
Cycle Repeatedly
Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks
Cycle Repeatedly > Page 2380
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly
Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 2386
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Technical Service Bulletins > Page 2387
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions
Body Controller: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2390
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2391
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2392
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2393
Body Controller: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2394
Body Controller: Connector Views
Body Control Module Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2395
Body Control Module Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2396
BCM Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2397
BCM Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Application and ID > BCM Identification
Body Controller: Application and ID BCM Identification
There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument
cluster.
- The other supports the electronic instrument cluster.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Application and ID > BCM Identification > Page 2400
Body Controller: Application and ID Glossary of Terms
BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Application and ID > Page 2401
Body Controller: Description and Operation
PURPOSE
The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these
systems.
- Is the only module that has the capability of providing both bias and termination on the CCD bus
system.
- Is used to store odometer information displayed in the electronic instrument cluster.
OPERATION
The body systems are monitored by individual control modules, which send information about their
operation to the body control module over the CCD (Chrysler Collision Detection multiplex system)
bus. Through the CCD bus, information about the operation of vehicle components and circuits is
relayed to the appropriate module(s).
- Each module receives the same information about a component or circuit as another module
does.
- This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
BODY SYSTEM COVERAGE:
- Automatic Door Locks
- Compass/mini-trip Module
- Courtesy Lamps
- Electronic Instrument Cluster (EIC)
- Electro/mechanical Instrument Cluster
- Mechanical Instrument Cluster (MIC)
- Illuminated Entry
- Remote Keyless Entry (RKE)
- Intermittent Wipers
- Liftgate Release
NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board
diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications
(CCD) Bus/Testing and Inspection for diagnosis and repair procedures.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
GLOSSARY OF TERMS
BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Testing and Inspection > Component Tests and General Diagnostics
Body Controller: Component Tests and General Diagnostics
Diagnostic Notes - Read First
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
NOTE: These diagnostics are based on the failure condition or symptom being present at the time
of diagnosis.
TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
Be careful when performing electrical tests to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components and will sometimes set a second code, making
diagnosis of the original problem more difficult.
WARNINGS:
- When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
- When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests.
To efficiently diagnose CCD bus problems follow these six steps:
1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5.
Repair the Isolated Problem 6. Verify Proper Operation
ROAD TESTING
Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and
to verify the repair.
CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled.
- During the test drive, do not try to read the scan tool screen while in motion.
- Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant
available to operate the scan tool.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
Description of On-Board Diagnostics
A scan tool is required to read body system trouble codes. However, not all body system problems
have a corresponding trouble code.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Testing and Inspection > Component Tests and General Diagnostics > Page 2404
Body Controller: Scan Tool Testing and Procedures
If the scan tool Does Not Power Up;
Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link
connector cavity 16).
If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully
charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information >
Testing and Inspection > Page 2405
Body Controller: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge
- Voltmeter
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Technical Service Bulletins > High Altitude Kit - Installation
Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation
NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993
SUBJECT: High Altitude Kits
MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
SYMPTOM/CONDITION:
The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st
page of the Starting and Operating section) that can be used if the owner changes his residence
from an area of low altitude to one of high altitude. These kits are required by the EPA for some
1994 federally certified AS body vehicles to comply with high altitude emissions standards. The
high altitude kit will have no effect on vehicle performance or driveability.
DIAGNOSIS:
Vehicles for which these kits are available have the following statement on the Vehicle Emission
Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE
OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at
the owner's expense.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label.
1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All
Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in
the "Parts Required" section of this bulletin.
2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of
the dash panel that the new labels will be attached to.
3. Attach the new VECI label on top of the original label.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Technical Service Bulletins > High Altitude Kit - Installation > Page 2410
4. Type in the required information on the Authorized Modification label (P/N 4275086) as
illustrated, and attach next to the VECI label.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Locations > Component Locations
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Locations > Component Locations > Page 2413
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2416
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2417
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2418
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2419
Powertrain Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2420
Powertrain Control Module 60 Way Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Locations > Page 2424
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Locations > Page 2425
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2428
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2429
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2430
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2431
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Page 2432
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Power Distribution Center (Relay Locations)
Fuel Pump Relay Socket
Fuel pump relay is located in LH side of engine compartment in the power distribution center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2439
Fuel Pump Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded
by the Powertrain Control Module (PCM).
OPERATION
The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM
is receiving reference signals from the distributor pick-up.
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater
element.
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2440
Fuel Pump Relay: Testing and Inspection
NOTE: The relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the component being operated.
- Terminal number 86 is connected to a switched (+) power source.
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 2444
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 2445
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2448
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2449
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2450
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2451
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 2452
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2460
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2461
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2462
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2463
Ignition Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 2470
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations >
Component Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations >
Component Locations > Page 2473
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2476
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2477
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2478
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2479
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2480
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2481
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2482
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2483
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications
Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications
NOTE: For information on how this type of sensor operates SEE, Powertrain
Management/Computers and Control Systems/Coolant Temperature Sensor/Description and
Operation.
NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM).
COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
-20° F ...................................................................................................................................................
....................................... 4.70 V
-10° F ...................................................................................................................................................
....................................... 4.57 V
0° F ......................................................................................................................................................
...................................... 4.45 V
10° F ....................................................................................................................................................
....................................... 4.30 V
20° F ....................................................................................................................................................
....................................... 4.10 V
30° F ....................................................................................................................................................
....................................... 3.90 V
40° F ....................................................................................................................................................
....................................... 3.60 V
50° F ....................................................................................................................................................
....................................... 3.30 V
60° F ....................................................................................................................................................
....................................... 3.00 V
70° F ....................................................................................................................................................
....................................... 2.75 V
80° F ....................................................................................................................................................
....................................... 2.44 V
90° F ....................................................................................................................................................
....................................... 2.15 V
100° F ..................................................................................................................................................
........................................ 1.83 V
110° F ..................................................................................................................................................
........................................ 1.57 V
120° F ..................................................................................................................................................
........................................ 1.25 V
HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
110° F ..................................................................................................................................................
........................................ 4.20 V
120° F ..................................................................................................................................................
........................................ 4.00 V
130° F ..................................................................................................................................................
........................................ 3.77 V
140° F ..................................................................................................................................................
........................................ 3.60 V
150° F ..................................................................................................................................................
........................................ 3.40 V
160° F ..................................................................................................................................................
........................................ 3.20 V
170° F ..................................................................................................................................................
........................................ 3.02 V
180° F ..................................................................................................................................................
........................................ 2.80 V
190° F ..................................................................................................................................................
........................................ 2.60 V
200° F ..................................................................................................................................................
........................................ 2.40 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 2488
210° F ..................................................................................................................................................
........................................ 2.20 V
220° F ..................................................................................................................................................
........................................ 2.00 V
230° F ..................................................................................................................................................
........................................ 1.80 V
240° F ..................................................................................................................................................
........................................ 1.62 V
250° F ..................................................................................................................................................
........................................ 1.45 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 2489
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 2490
Coolant Temperature Sensor/Switch (For Computer): Locations
Ignition Coil And Coolant Temperature Sensor Location
Sensor mounted under ignition coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2493
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2494
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2495
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2496
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2497
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Diagram Information and Instructions > Page 2498
Coolant Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Page 2499
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
LOCATION
The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the
thermostat housing.
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Page 2500
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Coolant Temperature Sensor Resistance Test
1. With key off, disconnect connector from coolant temperature sensor.
2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows;
- 700 to 1,000 Ohms at approximately 200°F (operating temperature).
- 7,000 to 13,000 ohms at approximately 70°F, (room temperature).
3. If resistance is not within specifications, replace sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams > Page 2501
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Ignition Coil And Coolant Temperature Sensor Location
REMOVAL
1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical
connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant
temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6.
Remove sensor from engine.
INSTALLATION
1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor.
3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12
Nm (105 in lbs) torque. 5. Connect electrical connector to coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Electrical Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 2506
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations >
Component Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations >
Component Locations > Page 2509
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2512
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2513
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2514
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2515
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2516
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2517
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
2518
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
2519
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Vacuum in Inches of Mercury MAP sensor Signal Voltage
.39 in Hg ..............................................................................................................................................
.............................. 4.90 V
3.34 in Hg ............................................................................................................................................
............................... 4.60 V
6.30 in Hg ............................................................................................................................................
............................... 3.60 V
9.25 in Hg ............................................................................................................................................
............................... 3.10 V
12.20 in Hg ..........................................................................................................................................
................................ 2.60 V
15.15 in Hg ..........................................................................................................................................
................................ 2.10 V
18.11 in Hg ..........................................................................................................................................
................................ 1.60 V
21.06 in Hg ..........................................................................................................................................
................................ 1.10 V
24.01 in Hg ..........................................................................................................................................
................................ 0.60 V
26.97 in Hg ..........................................................................................................................................
................................ 0.31 V
Condition .............................................................................................................................................
.................................. Expected Output Voltage
High Vacuum (Idle/Deceleration)
.............................................................................................................................................................
0.5 to 1.5 volts
Medium Vacuum (Cruise/Slight Acceleration)
......................................................................................................................................... 1.5 to 3.0
volts
Low Vacuum (Hard Acceleration/Mechanical Failure)
............................................................................................................................. 3.0 to 4.5 volts
NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Control Component Locations
Back Side Of Intake Plenum View
Sensor mounted on back side of intake plenum.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2525
Back Side Of Intake Plenum View
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions
Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 2528
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 2529
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 2530
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 2531
Manifold Pressure/Vacuum Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 2532
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 2533
MAP Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Page 2534
Manifold Pressure/Vacuum Sensor: Description and Operation
LOCATION
Sensor mounted on intake plenum.
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts.
- Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Page 2535
Manifold Pressure/Vacuum Sensor: Testing and Inspection
NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its
circuitry, refer to appropriate Diagnostic Chart. See: Computers and Control Systems/Testing and
Inspection
TO TEST THE MAP SENSOR ONLY:
1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary.
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition
switch ON, and the engine OFF. Output voltage
should be 4 to 5 volts.
3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle
speed condition. The voltage should drop to 1.5
to 2.1 volts.
4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness
condition. Repair as necessary.
5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage
should be approximately 5 volts (±O.5 V). 5
volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair
or replace the wire harness as necessary.
6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal
/ pin-4. Repair the wire harness if necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams >
Page 2536
Manifold Pressure/Vacuum Sensor: Service and Repair
MAP" Sensor
Removal
1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting
screws and remove sensor.
Installation
1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Oxygen Sensor: Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations
Oxygen Sensor: Component Locations
EGR Mounting
Sensor threaded into exhaust manifold, just above flange.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2542
Back Side Of Intake Plenum View
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2545
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2546
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2547
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2548
Oxygen Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2549
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2550
Oxygen Sensor: Electrical Diagrams
Oxygen Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2551
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2552
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 2555
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 2556
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
Oxygen Sensor And Connector
Oxygen Sensor Connector Identification And PINOUT
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground
(terminals 3 and 4), of the sensor electrical
connector.
3. Resistance should be between 5 and 7 ohms, if not replace the sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page
2557
Oxygen Sensor: Service and Repair
Oxygen Sensor Location (Typical)
Oxygen Sensor Socket
WARNING: Avoid physical contact with hot exhaust components.
CAUTION: Do not pull on or cut sensor wires, when removing sensor.
CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL
1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket
YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly
tightening the
sensor before removal may ease removal.)
3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap.
INSTALLATION
1. If a new sensor is being used, verify that the threads are coated with anti-seize compound,
before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel
based anti-seize compound, (Loctite 771-64 or equivalent).
CAUTION: Do not use graphite or other anti-seize compounds.
3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or
Delayed Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2571
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 2574
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2577
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2578
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2579
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2580
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2581
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2582
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2583
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2584
Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2585
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2586
Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2595
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 (V6-201 3.3L (1994))
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 2596
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 (V6-201 3.3L (1994))
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 2597
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2603
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 (V6-201 3.3L (1994))
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 2604
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2609
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 (V6-201 3.3L (1994))
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 2610
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 (V6-201 3.3L (1994))
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 2611
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2617
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 (V6-201 3.3L (1994))
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 2618
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2621
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2622
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2625
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2628
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 2631
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 (V6-201 3.3L (1994))
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 2632
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component
Locations
Vehicle Speed Sensor: Component Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component
Locations > Page 2637
Vehicle Speed Sensor: Connector Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2640
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2641
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2642
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2643
Vehicle Speed Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2644
Vehicle Speed Sensor: Electrical Diagrams
Vehicle Speed Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2645
Vehicle Speed Sensor: Description and Operation
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or
Delayed Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2660
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 2663
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2666
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2667
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2668
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2669
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2670
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2671
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2672
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2673
Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2674
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2675
Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 2681
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations >
Page 2684
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2687
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2688
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2689
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2690
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2691
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2692
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2693
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2694
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 2699
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations >
Page 2702
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2705
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2706
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2707
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 2708
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2709
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 2710
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2711
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2712
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition
Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition
Cylinder Addition
NUMBER: 23-44-94D
GROUP: Body
DATE: Jun. 3, 1994
Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105
DISCUSSION:
A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle
security.
The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a
bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove
the screw.
The 1995 Dakota service manual was completed prior to this information being available to Service
Publications. The vehicles listed as 1994 models only, will have this information already in their
corresponding 1995 service manual.
DESCRIPTION OF CHANGES
Add Tamper Resistant Ignition Key Cylinder Info.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2718
8D - 37
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2719
8D - 38
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2720
8D - 39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2721
8D - 39A
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Specifications > Page 2730
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through
Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable,
inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform
minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES
MINIMUM AIRFLOW TEST IDLE SPEED
ODOMETER READING IDLE SPEED
Less than 1000 miles 525-875 RPM
More than 1000 miles 575-875 RPM
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > Page 2734
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 (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Fuel Pressure Release Procedure - Typical
WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even
when the engine is OFF.
1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3.
Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose,
tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this
hose to
the fuel rail service port. Fuel pressure should bleed off into container.
5. Perform necessary fuel system service procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Timing Marks and Indicators > System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates
Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2757
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2758
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec
> 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec
> 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2764
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec
> 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2765
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Page 2766
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Page 2767
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
Purpose
Transfer electrical current from the distributor to individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2770
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables
must be released from inside the distributor cap.
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic
converter. Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an
open circuit or other damage.
INSPECTION
Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully
seated, and the nipples and spark plug covers should be in good condition.
Covers should fit tightly on the coil, distributor cap towers and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
RESISTANCE TEST
Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
Remove cable from spark plug.
Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables
must be removed from the spark plugs.
Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside
the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance
shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower
and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all
spark plug cables in same manner.
To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not
remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove
the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the
cable. Also, check for a loose connection at the tower or for a faulty coil.
Inspect coil tower for cracks or carbon tracking.
Secondary Ignition Cable Resistance Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten
minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
SPARK PLUG CABLES
1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not
remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the
ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure
probes make good contact.
Resistance should be within tolerance.
4. If the resistance is not within tolerance, remove cable at cap tower and check the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2771
5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in
same manner.
COIL TO DISTRIBUTOR HIGH TENSION CABLE
1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the
cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of
cable. 4. If resistance is not within tolerance, replace the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap Specifications
Spark Plug: Specifications Gap Specifications
NOTE: 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.
Spark Plug Gap ...................................................................................................................................
............................... 1.2 to 1.3 mm (0.048 to 0.053 in)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap Specifications > Page 2776
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
....................................................... 28 Nm (20 ft-lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2777
Spark Plug: Description and Operation
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for
spark plug diagnosis.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2780
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2781
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2782
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2783
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2784
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2785
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2786
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
PROCEDURE
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Page 2787
Spark Plug: Adjustments
Setting Spark Plug Electrode Gap
Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the
ground -- center electrode.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Service and Repair > Replacement Notes
Spark Plug: Service and Repair Replacement Notes
TIP: Always keep plugs in the order they were removed. Any plug that looks different from other
plugs indicates a problem in that cylinder.
NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and
Inspection/Procedures
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Service and Repair > Replacement Notes > Page 2790
Spark Plug: Service and Repair Removal and Installation
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
REMOVAL
1. Spray compressed air around spark plug to prevent foreign material from entering combustion
chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back
in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR:
- Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION
1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Cylinder Compression Pressure 100 psi
NOTE: No more than 25% variance between cylinders.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2794
Compression Check: Service Precautions
COMPRESSION TESTING
When performing a compression test, remove the fuel pump relay fuse and disconnect power to
the ignition. This will stop fuel flow to the injectors and prevent engine from starting.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2795
Compression Check: Testing and Inspection
PROCEDURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. 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. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For
Direct Ignition System (DIS) disconnect the coil connector.
5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage.
Record this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689
kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem
in the cylinder in question. The recommended compression pressures are to be used only as a
guide to diagnosing engine problems. An engine should not be disassembled to determine the
cause of low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16.
Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test
vehicle as a final test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Adjustments
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters, no adjustment is necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component
Information > Description and Operation
A/C Signal: Description and Operation
PURPOSE
Powertrain Control Module (PCM) monitors engine load and A/C system pressure, and cycles the
A/C compressor clutch accordingly.
CONDITIONS
A/C or Defrost switch ON.
Combination valve, A/C low pressure and high pressure switches are closed.
OPERATION
Powertrain Control Module (PCM) receives an A/C selected signal.
- PCM engages A/C compressor clutch (by grounding clutch relay).
- PCM cycles compressor clutch depending on engine load and A/C system pressure.
- PCM maintains correct engine idle speed, through the Idle Air Control (IAC) Motor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed)
> Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise
Auxiliary Air Valve (Idle Speed): Technical Service Bulletins Idle Air Control Motor - Whistling Noise
NO.: 14-09-93 Rev.A
GROUP: Fuel
DATE: Nov. 12, 1993
SUBJECT: Idle Air Control Motor Whistle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED
6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION.
MODELS:
** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth
Avenue
1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country**
1993 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
**NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH
1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.**
SYMPTOM/CONDITION:
Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may
be more prevalent when the engine is under a load such as air conditioning or headlamps on. No
whistling can be heard while cruising.
DIAGNOSIS:
**Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for
several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment.
Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away,
perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin
No. 21-01-93 published 1-13-93.**
PARTS REQUIRED:
1 4612673 Idle Air Control Motor
REPAIR PROCEDURE:
This bulletin involves the replacement of the idle air control motor.
1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control
motor.
2. Run the engine at idle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
14-30-23-96 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 >
Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 >
Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 2815
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller:
> 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller:
> 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 2821
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Technical Service Bulletins > Page 2822
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions
Body Controller: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2825
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2826
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2827
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2828
Body Controller: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2829
Body Controller: Connector Views
Body Control Module Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2830
Body Control Module Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2831
BCM Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2832
BCM Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Application and ID > BCM Identification
Body Controller: Application and ID BCM Identification
There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument
cluster.
- The other supports the electronic instrument cluster.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Application and ID > BCM Identification > Page 2835
Body Controller: Application and ID Glossary of Terms
BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Application and ID > Page 2836
Body Controller: Description and Operation
PURPOSE
The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these
systems.
- Is the only module that has the capability of providing both bias and termination on the CCD bus
system.
- Is used to store odometer information displayed in the electronic instrument cluster.
OPERATION
The body systems are monitored by individual control modules, which send information about their
operation to the body control module over the CCD (Chrysler Collision Detection multiplex system)
bus. Through the CCD bus, information about the operation of vehicle components and circuits is
relayed to the appropriate module(s).
- Each module receives the same information about a component or circuit as another module
does.
- This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
BODY SYSTEM COVERAGE:
- Automatic Door Locks
- Compass/mini-trip Module
- Courtesy Lamps
- Electronic Instrument Cluster (EIC)
- Electro/mechanical Instrument Cluster
- Mechanical Instrument Cluster (MIC)
- Illuminated Entry
- Remote Keyless Entry (RKE)
- Intermittent Wipers
- Liftgate Release
NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board
diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications
(CCD) Bus/Testing and Inspection for diagnosis and repair procedures.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
GLOSSARY OF TERMS
BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics
Body Controller: Component Tests and General Diagnostics
Diagnostic Notes - Read First
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
NOTE: These diagnostics are based on the failure condition or symptom being present at the time
of diagnosis.
TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
Be careful when performing electrical tests to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components and will sometimes set a second code, making
diagnosis of the original problem more difficult.
WARNINGS:
- When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
- When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests.
To efficiently diagnose CCD bus problems follow these six steps:
1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5.
Repair the Isolated Problem 6. Verify Proper Operation
ROAD TESTING
Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and
to verify the repair.
CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled.
- During the test drive, do not try to read the scan tool screen while in motion.
- Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant
available to operate the scan tool.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
Description of On-Board Diagnostics
A scan tool is required to read body system trouble codes. However, not all body system problems
have a corresponding trouble code.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page
2839
Body Controller: Scan Tool Testing and Procedures
If the scan tool Does Not Power Up;
Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link
connector cavity 16).
If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully
charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body
Control Module] > Component Information > Testing and Inspection > Page 2840
Body Controller: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge
- Voltmeter
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation
Brake Signal: Description and Operation
LOCATION
Sensor mounted on brake pedal support bracket.
PURPOSE
Powertrain Control Module (PCM) uses switch input to control idle speed and speed control.
OPERATION
PCM vents speed control system vacuum and turns speed control system OFF when appraised of
a brake switch actuation.
PCM prevents engine stall during rapid decel, by actuating Idle Air Control (IAC) motor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Electrical Specifications > Page 2848
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Component Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Component Locations > Page 2851
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2854
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2855
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2856
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2857
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2858
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2859
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2860
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2861
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications
Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications
NOTE: For information on how this type of sensor operates SEE, Powertrain
Management/Computers and Control Systems/Coolant Temperature Sensor/Description and
Operation.
NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM).
COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
-20° F ...................................................................................................................................................
....................................... 4.70 V
-10° F ...................................................................................................................................................
....................................... 4.57 V
0° F ......................................................................................................................................................
...................................... 4.45 V
10° F ....................................................................................................................................................
....................................... 4.30 V
20° F ....................................................................................................................................................
....................................... 4.10 V
30° F ....................................................................................................................................................
....................................... 3.90 V
40° F ....................................................................................................................................................
....................................... 3.60 V
50° F ....................................................................................................................................................
....................................... 3.30 V
60° F ....................................................................................................................................................
....................................... 3.00 V
70° F ....................................................................................................................................................
....................................... 2.75 V
80° F ....................................................................................................................................................
....................................... 2.44 V
90° F ....................................................................................................................................................
....................................... 2.15 V
100° F ..................................................................................................................................................
........................................ 1.83 V
110° F ..................................................................................................................................................
........................................ 1.57 V
120° F ..................................................................................................................................................
........................................ 1.25 V
HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
110° F ..................................................................................................................................................
........................................ 4.20 V
120° F ..................................................................................................................................................
........................................ 4.00 V
130° F ..................................................................................................................................................
........................................ 3.77 V
140° F ..................................................................................................................................................
........................................ 3.60 V
150° F ..................................................................................................................................................
........................................ 3.40 V
160° F ..................................................................................................................................................
........................................ 3.20 V
170° F ..................................................................................................................................................
........................................ 3.02 V
180° F ..................................................................................................................................................
........................................ 2.80 V
190° F ..................................................................................................................................................
........................................ 2.60 V
200° F ..................................................................................................................................................
........................................ 2.40 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2866
210° F ..................................................................................................................................................
........................................ 2.20 V
220° F ..................................................................................................................................................
........................................ 2.00 V
230° F ..................................................................................................................................................
........................................ 1.80 V
240° F ..................................................................................................................................................
........................................ 1.62 V
250° F ..................................................................................................................................................
........................................ 1.45 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2867
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2868
Coolant Temperature Sensor/Switch (For Computer): Locations
Ignition Coil And Coolant Temperature Sensor Location
Sensor mounted under ignition coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2871
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2872
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2873
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2874
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2875
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2876
Coolant Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2877
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
LOCATION
The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the
thermostat housing.
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2878
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Coolant Temperature Sensor Resistance Test
1. With key off, disconnect connector from coolant temperature sensor.
2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows;
- 700 to 1,000 Ohms at approximately 200°F (operating temperature).
- 7,000 to 13,000 ohms at approximately 70°F, (room temperature).
3. If resistance is not within specifications, replace sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2879
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Ignition Coil And Coolant Temperature Sensor Location
REMOVAL
1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical
connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant
temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6.
Remove sensor from engine.
INSTALLATION
1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor.
3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12
Nm (105 in lbs) torque. 5. Connect electrical connector to coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Electrical Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Electrical Specifications > Page 2884
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Component Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Component Locations > Page 2887
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2890
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2891
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2892
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2893
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2894
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2895
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Page 2896
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Page 2897
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Technical Service Bulletins > Diagnostic Connector - Change
Data Link Connector: Technical Service Bulletins Diagnostic Connector - Change
NO: 08-23-94
GROUP: Electrical
DATE: May 13, 1994
SUBJECT: Diagnostic Connector Change
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
During March, 1994 the diagnostic connector located near the steering column at the bottom of the
instrument panel was changed from a blue 6-way connector to a black 8-way connector.
Even though the Scan Tool (DRBII/III) has a 6-way connector, the indexing of the 8-way diagnostic
connector permits the 6-way DRBII/III connector to mate with it. No special service procedures are
required when mating the two connectors. The additional two pins are used during the vehicle
assembly process.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Technical Service Bulletins > Page 2902
Data Link Connector: Locations
Powertrain Control Module (PCM) And Data Link Connector
Connector on left side of engine compartment, near battery.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Technical Service Bulletins > Page 2903
Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Description and Operation > Data Link Connector
Data Link Connector: Description and Operation Data Link Connector
Powertrain Control Module (PCM) And Data Link Connector
LOCATION
Left side of engine compartment, near battery.
Data Link Connector Identification
PURPOSE
Communication link to Powertrain Control Module (PCM)
Technician can access inputs and memory including:
- Sensor input values
- Diagnostic Trouble Codes (DTC's) stored in memory
- Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or
no crank sensor signal).
Technician can actuate most PCM output devices.
NOTE: Monitoring inputs, reading other memory and actuating output devices can only be
accomplished through the use of a scan tool. SEE TESTING AND INSPECTION.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Description and Operation > Data Link Connector > Page 2906
Data Link Connector: Description and Operation SCI Receive
The SCI receive circuit is used as a communication path for the scan tool. The scan tool receives
data through this circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Description and Operation > Data Link Connector > Page 2907
Data Link Connector: Description and Operation SCI Transmit
PURPOSE
Powertrain Control Module (PCM) sends data to the scan tool through this circuit, including;
- Sensor input values
- Diagnostic Trouble Codes (DTC's) stored in memory
- Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or
no crank sensor signal).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <-->
[EGR Backpressure Transducer] > Component Information > Locations
Electric EGR Transducer: Locations
EGR Mounting
Electric EGR Transducer (EET)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <-->
[EGR Backpressure Transducer] > Component Information > Locations > Page 2911
EGR System
Mounted near the throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <-->
[EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer
Operation
Electric EGR Transducer: Description and Operation Backpressure Transducer Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a
backpressure transducer, in one package. PURPOSE
When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR
valve control nipple, (depending on engine load conditions).
OPERATION
Transducer is supplied ported vacuum through the solenoid.
Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no
vacuum is applied to the EGR valve.
- When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and
maximum vacuum is applied to the EGR valve.
- When exhaust backpressure is present, but not great enough to close the vacuum bleed valve
completely, the vacuum applied to the EGR valve varies with the backpressure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <-->
[EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer
Operation > Page 2914
Electric EGR Transducer: Description and Operation Electric EGR Transducer (EET)
Vacuum Control Solenoid Valve Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The EET assembly is a vacuum control solenoid and a backpressure transducer, in one
package. PURPOSE
The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the
Electronic EGR Transducer (EET).
OPERATION
Ported vacuum from the throttle body, is supplied to the solenoid valve.
The PCM controls the flow of vacuum between the throttle body and the back pressure transducer,
(through the solenoid ground circuit).
- When the solenoid is energized (grounded), no vacuum is supplied to the transducer.
- When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer.
The solenoid will always be energized (no EGR), under following conditions:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <-->
[EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer
Operation > Page 2915
- Engine warm-up, (engine coolant temperature below 40 ~F)
- Engine at idle
- Wide Open Throttle (WOT) operation
- Rapid acceleration/deceleration
- During EGR system diagnostic check
NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at
all times, (adversely affecting engine idle and performance).
Backpressure Transducer Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a
backpressure transducer, in one package. PURPOSE
When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR
valve control nipple, (depending on engine load conditions).
OPERATION
Transducer is supplied ported vacuum through the solenoid.
Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no
vacuum is applied to the EGR valve.
- When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and
maximum vacuum is applied to the EGR valve.
- When exhaust backpressure is present, but not great enough to close the vacuum bleed valve
completely, the vacuum applied to the EGR valve
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <-->
[EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer
Operation > Page 2916
varies with the backpressure.
Diagnostic Check Operation
The solenoid disables the EGR system periodically, to allow the PCM to perform a diagnostic
check.
- During a diagnostic check, (activated only during select engine/driving conditions), the PCM tests
the entire EGR system for failures.
- If the PCM detects an EGR system failure, the Malfunction Indicator Lamp (MIL), (previously
called the Check Engine Lamp), in the instrument panel will be illuminated, indicating that
immediate service is required.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <-->
[EGR Backpressure Transducer] > Component Information > Description and Operation > Page 2917
Electric EGR Transducer: Service and Repair
EGR Mounting
REMOVAL
1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for
any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove
transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for
signs of leakage or cracks.
INSTALLATION
1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install
transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and
electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation
Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation
NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993
SUBJECT: High Altitude Kits
MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
SYMPTOM/CONDITION:
The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st
page of the Starting and Operating section) that can be used if the owner changes his residence
from an area of low altitude to one of high altitude. These kits are required by the EPA for some
1994 federally certified AS body vehicles to comply with high altitude emissions standards. The
high altitude kit will have no effect on vehicle performance or driveability.
DIAGNOSIS:
Vehicles for which these kits are available have the following statement on the Vehicle Emission
Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE
OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at
the owner's expense.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label.
1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All
Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in
the "Parts Required" section of this bulletin.
2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of
the dash panel that the new labels will be attached to.
3. Attach the new VECI label on top of the original label.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation > Page
2922
4. Type in the required information on the Authorized Modification label (P/N 4275086) as
illustrated, and attach next to the VECI label.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Locations > Component Locations
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Locations > Component Locations > Page 2925
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2928
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2929
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2930
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2931
Powertrain Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2932
Powertrain Control Module 60 Way Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise
Idle Speed/Throttle Actuator - Electronic: Technical Service Bulletins Idle Air Control Motor Whistling Noise
NO.: 14-09-93 Rev.A
GROUP: Fuel
DATE: Nov. 12, 1993
SUBJECT: Idle Air Control Motor Whistle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED
6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION.
MODELS:
** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth
Avenue
1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country**
1993 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
**NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH
1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.**
SYMPTOM/CONDITION:
Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may
be more prevalent when the engine is under a load such as air conditioning or headlamps on. No
whistling can be heard while cruising.
DIAGNOSIS:
**Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for
several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment.
Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away,
perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin
No. 21-01-93 published 1-13-93.**
PARTS REQUIRED:
1 4612673 Idle Air Control Motor
REPAIR PROCEDURE:
This bulletin involves the replacement of the idle air control motor.
1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control
motor.
2. Run the engine at idle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
14-30-23-96 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 2939
Idle Speed/Throttle Actuator - Electronic: Connector Locations
Throttle Body View With Idle Air Control Motor
- Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions
Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2942
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2943
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2944
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2945
Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2946
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2947
Idle Air Control Motor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2948
Idle Speed/Throttle Actuator - Electronic: Description and Operation
Throttle Body View With Idle Air Control Motor
LOCATION
Mounted on throttle body.
PURPOSE
Maintains optimum idle speed under varying engine loads.
Prevents deceleration die out.
OPERATION
Powertrain Control Module (PCM) calculates proper idle speed using information from throttle
position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches.
PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body.
Prevents decel die out by increasing air flow when throttle is closed suddenly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2949
Idle Speed/Throttle Actuator - Electronic: Testing and Inspection
NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool.
CAUTION: Proper safety precautions must be taken when testing the IAC motor.
- Set the parking brake and block the drive wheels
- Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust
components
- Provide proper ventilation while operating the engine
- Always return the engine idle speed to normal before disconnecting the exerciser tool.
- Follow scan tool manufacturer's instructions for testing the IAC motor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2950
Idle Speed/Throttle Actuator - Electronic: Service and Repair
Throttle Body View With Idle Air Control Motor
Removal
1. Disconnect the negative battery cable. 2. Disconnect motor wiring connector. 3. Remove motor
mounting screws (2-25 mm long, Torx head screws), and remove motor, (make sure the O-ring is
removed from throttle body).
Idle Air Control (IAC) Motor Installation
Installation
NOTE: If the pintle measures more than 1 in (25 mm), it must be retracted using scan tool [1].
1. Install motor using a new O-ring, and torque mounting screws to 20 in-lbs (2 Nm). 2. Connect
motor wiring connector. 3. Install air cleaner assembly. 4. Connect negative battery cable.
Remarks
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2951
[1] Follow scan tool manufacturer's instructions.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Locations > CCD Data Link Connector Location
Information Bus: Locations CCD Data Link Connector Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Locations > CCD Data Link Connector Location > Page 2956
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Service Precautions > Technician Safety Information
Information Bus: Technician Safety Information
- When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make inadvertent electrical contact.
- When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests.
- Some components of the body system are intended to be serviced in assembly only. Attempting
to remove or repair certain system sub-components may result in personal injury and/or improper
system operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Service Precautions > Technician Safety Information > Page 2959
Information Bus: Vehicle Damage Warnings
- Make sure the ignition is OFF before disconnecting any control module. Failure to do so could
damage the module.
- When testing voltage or continuity at any control module, use the terminal side (not the wire end)
of the connector. Do not probe a wire through the insulation; this will damage it and eventually
cause it to fail due to corrosion.
- Be careful when performing electrical tests to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components and will sometimes set a second code, making
diagnosis of the original problem more difficult.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Application and ID > Glossary of Terms
Information Bus: Application and ID Glossary of Terms
ACM - Air Bag Control Module ATC - Automatic Temperature Control BCM - Body Control Module
CAB - Controller-Antilock Brake CCD - Chrysler Collision Detection (vehicle communications bus)
EIC - Electronic Instrument Cluster MIC - Mechanical Instrument Cluster PCM - Powertrain Control
Module TCM - Transmission Control Module VTSS - Vehicle Theft Security System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Application and ID > Glossary of Terms > Page 2962
Information Bus: Application and ID Vehicle Body Code ID
CARS
AA Chrysler LeBaron (4-door), Dodge Spirit, Plymouth Acclaim
AC Chrysler New Yorker Salon, Dodge Dynasty
AG Dodge Daytona
AJ Chrysler LeBaron (2-door)
AP Dodge Shadow, Plymouth Sundance
AS Chrysler Town and Country, Dodge Caravan and Grand Caravan, Plymouth Voyager and
Grand Voyager
AY Chrysler Imperial, Chrysler Fifth Avenue
FJ22 Chrysler Sebring Dodge Avenger
FJ24 Eagle Talon
JA Chrysler Cirrus Plymouth Cirrus Dodge Stratus
LH Chrysler Concorde Chrysler, LHS, Chrysler New Yorker, Dodge Intrepid, Eagle Vision
PL Dodge Neon, Plymouth Neon
SR Dodge Viper
TRUCKS
AB Dodge Ram (Van / Wagon) 150, 250, 350
AD Dodge Ram (Pickup) 150, 250, 350 Dodge Ramcharger
AN Dodge Dakota
BR Dodge Ram (Pickup) 1500, 2500, 3500
BT Dodge Ram (Cab) 1500, 2500, 3500
ES Chrysler Grand Voyager, Chrysler Ram Van
MJ Jeep Comanche
XJ Jeep Cherokee
YJ Jeep Wrangler
ZJ Jeep Grand Cherokee
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > CCD Bus
Information Bus: Description and Operation CCD Bus
PURPOSE:
The CCD bus relays information about the operation of vehicle components and circuits to the
appropriate module(s).
OPERATION
The body system consists of a combination of modules that communicate over the Chrysler
Collision Detection multiplex system (CCD bus).
Each module receives the same information about a component or circuit as the other modules do.
This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
The CCD Bus may be used for communication between the Vehicle Theft Alarm (VTA) module,
instrument panel, scan tool, and the Powertrain Control Module (PCM).
The CCD Bus is both an input and output from the Vehicle Theft Alarm (VTA) module. Circuit D1 is
used for CCD (+) and circuit D2 is used for CCD (-). These circuits are connected in with the data
link connector and the Powertrain Control Module (PCM).
Bus Information is Coded The CCD bus receives and delivers coded information between the
modules. The information is coded to identify the message as well as the importance of the message.
- When there are multiple messages trying to access the CCD bus at one time, the message with
higher priority is allowed to access the bus first.
Twisted Pair CCD bus consists of a twisted pair of wires that run from one module to another. The two wires (D1) and (D2) of the twisted pair that make up the CCD multiplex system are called
"bus +", (bus plus) and "bus -", (bus minus) respectively.
- Each wire has a measurable voltage level of roughly 2.5 volts.
Voltage Divider Network Bias and Termination In order to maintain the 2.5 volts on each line and
provide a means of transportation for the coded messages, there is a "voltage divider network."
This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus+ and bus- at 2.5 volts.
- Termination in the circuitry is required to complete the voltage divider network and also to provide
some electromagnetic protection for the bus.
NOTE: Modules using the CCD bus can be identified by accessing them through the CCD bus
using a scan tool with the correct connector and cartridge.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > CCD Bus > Page 2965
Information Bus: Description and Operation Modules Connected to Body Control Module
Some of the instructions tell you to disconnect a module that may not be available on this vehicle.
Above is a matrix of modules and bodies showing the modules each vehicle is equipped with.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Component Tests and General Diagnostics
Information Bus: Component Tests and General Diagnostics
NOTE: Use these procedures only when instructed to do so by another test procedure.
TIP: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
CAUTION: Be careful when performing electrical tests to prevent accidental shorting of terminals.
Such mistakes can damage fuses or components and will sometimes set a second code, making
diagnosis of the original problem more difficult.
To efficiently diagnose CCD bus problems follow these six steps:
1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5.
Repair the Isolated Problem 6. Verify Proper Operation
ROAD TESTING
Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and
to verify the repair.
CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled.
- During the test drive, do not try to read the scan tool screen while in motion.
- Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant
available to operate the scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Page 2968
Information Bus: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and connector
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge
- Voltmeter
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2972
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2973
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 2976
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 2977
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 2978
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 2979
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2980
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Locations
Malfunction Indicator Lamp: Locations
NOTE: MIL previously called Check Engine Lamp (CEL).
Light in instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Locations > Page 2986
Malfunction Indicator Lamp: Description and Operation
NOTE: Malfunction Indicator Lamp (MIL), previously called Check Engine Lamp (CEL). PURPOSE
Indicates immediate service of engine control system is required.
Informs driver that he has entered "Limp-In" mode, lamp ON while vehicle is being driven.
Displays Diagnostic Trouble Codes (DTC's), stored in memory.
OPERATION
Illuminates for three seconds when ignition switch is turned ON, (for bulb test).
Illuminates if Powertrain Control Module (PCM) receives an out of range input from a monitored
circuit, or, (for vehicles with California emissions), from an emission related device.
- Signals that can set Malfunction Indicator Lamp are battery voltage input, charging system,
Manifold Absolute Pressure (MAP), sensor, Throttle Position Sensor (TPS), Engine Coolant
Temperature (ECT) sensor.
Can be used to display any DTC's stored in memory, SEE POWERTRAIN
MANAGEMENT/COMPUTERS AND CONTROL SYSTEMS/TESTING AND INSPECTION.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Vacuum in Inches of Mercury MAP sensor Signal Voltage
.39 in Hg ..............................................................................................................................................
.............................. 4.90 V
3.34 in Hg ............................................................................................................................................
............................... 4.60 V
6.30 in Hg ............................................................................................................................................
............................... 3.60 V
9.25 in Hg ............................................................................................................................................
............................... 3.10 V
12.20 in Hg ..........................................................................................................................................
................................ 2.60 V
15.15 in Hg ..........................................................................................................................................
................................ 2.10 V
18.11 in Hg ..........................................................................................................................................
................................ 1.60 V
21.06 in Hg ..........................................................................................................................................
................................ 1.10 V
24.01 in Hg ..........................................................................................................................................
................................ 0.60 V
26.97 in Hg ..........................................................................................................................................
................................ 0.31 V
Condition .............................................................................................................................................
.................................. Expected Output Voltage
High Vacuum (Idle/Deceleration)
.............................................................................................................................................................
0.5 to 1.5 volts
Medium Vacuum (Cruise/Slight Acceleration)
......................................................................................................................................... 1.5 to 3.0
volts
Low Vacuum (Hard Acceleration/Mechanical Failure)
............................................................................................................................. 3.0 to 4.5 volts
NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Control Component Locations
Back Side Of Intake Plenum View
Sensor mounted on back side of intake plenum.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Component Locations > Page 2992
Back Side Of Intake Plenum View
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Diagram Information and Instructions
Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2995
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2996
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2997
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2998
Manifold Pressure/Vacuum Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2999
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3000
MAP Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Page 3001
Manifold Pressure/Vacuum Sensor: Description and Operation
LOCATION
Sensor mounted on intake plenum.
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts.
- Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Page 3002
Manifold Pressure/Vacuum Sensor: Testing and Inspection
NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its
circuitry, refer to appropriate Diagnostic Chart. See: Testing and Inspection
TO TEST THE MAP SENSOR ONLY:
1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary.
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition
switch ON, and the engine OFF. Output voltage
should be 4 to 5 volts.
3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle
speed condition. The voltage should drop to 1.5
to 2.1 volts.
4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness
condition. Repair as necessary.
5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage
should be approximately 5 volts (±O.5 V). 5
volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair
or replace the wire harness as necessary.
6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal
/ pin-4. Repair the wire harness if necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Diagrams > Page 3003
Manifold Pressure/Vacuum Sensor: Service and Repair
MAP" Sensor
Removal
1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting
screws and remove sensor.
Installation
1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Specifications
Oxygen Sensor: Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations
Oxygen Sensor: Component Locations
EGR Mounting
Sensor threaded into exhaust manifold, just above flange.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations > Page 3009
Back Side Of Intake Plenum View
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Oxygen Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3012
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3013
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3014
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3015
Oxygen Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3016
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3017
Oxygen Sensor: Electrical Diagrams
Oxygen Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 3018
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 3019
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Testing and Inspection > Powertrain Control Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3022
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3023
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
Oxygen Sensor And Connector
Oxygen Sensor Connector Identification And PINOUT
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground
(terminals 3 and 4), of the sensor electrical
connector.
3. Resistance should be between 5 and 7 ohms, if not replace the sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Testing and Inspection > Page 3024
Oxygen Sensor: Service and Repair
Oxygen Sensor Location (Typical)
Oxygen Sensor Socket
WARNING: Avoid physical contact with hot exhaust components.
CAUTION: Do not pull on or cut sensor wires, when removing sensor.
CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL
1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket
YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly
tightening the
sensor before removal may ease removal.)
3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap.
INSTALLATION
1. If a new sensor is being used, verify that the threads are coated with anti-seize compound,
before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel
based anti-seize compound, (Loctite 771-64 or equivalent).
CAUTION: Do not use graphite or other anti-seize compounds.
3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle
Repeatedly
Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle
Repeatedly > Page 3034
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly
Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 3040
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical
Service Bulletins > Page 3041
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions
Body Controller: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3044
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3045
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3046
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3047
Body Controller: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3048
Body Controller: Connector Views
Body Control Module Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3049
Body Control Module Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3050
BCM Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3051
BCM Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and
ID > BCM Identification
Body Controller: Application and ID BCM Identification
There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument
cluster.
- The other supports the electronic instrument cluster.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and
ID > BCM Identification > Page 3054
Body Controller: Application and ID Glossary of Terms
BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and
ID > Page 3055
Body Controller: Description and Operation
PURPOSE
The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these
systems.
- Is the only module that has the capability of providing both bias and termination on the CCD bus
system.
- Is used to store odometer information displayed in the electronic instrument cluster.
OPERATION
The body systems are monitored by individual control modules, which send information about their
operation to the body control module over the CCD (Chrysler Collision Detection multiplex system)
bus. Through the CCD bus, information about the operation of vehicle components and circuits is
relayed to the appropriate module(s).
- Each module receives the same information about a component or circuit as another module
does.
- This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
BODY SYSTEM COVERAGE:
- Automatic Door Locks
- Compass/mini-trip Module
- Courtesy Lamps
- Electronic Instrument Cluster (EIC)
- Electro/mechanical Instrument Cluster
- Mechanical Instrument Cluster (MIC)
- Illuminated Entry
- Remote Keyless Entry (RKE)
- Intermittent Wipers
- Liftgate Release
NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board
diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications
(CCD) Bus/Testing and Inspection for diagnosis and repair procedures.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
GLOSSARY OF TERMS
BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and
Inspection > Component Tests and General Diagnostics
Body Controller: Component Tests and General Diagnostics
Diagnostic Notes - Read First
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
NOTE: These diagnostics are based on the failure condition or symptom being present at the time
of diagnosis.
TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
Be careful when performing electrical tests to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components and will sometimes set a second code, making
diagnosis of the original problem more difficult.
WARNINGS:
- When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
- When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests.
To efficiently diagnose CCD bus problems follow these six steps:
1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5.
Repair the Isolated Problem 6. Verify Proper Operation
ROAD TESTING
Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and
to verify the repair.
CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled.
- During the test drive, do not try to read the scan tool screen while in motion.
- Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant
available to operate the scan tool.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
Description of On-Board Diagnostics
A scan tool is required to read body system trouble codes. However, not all body system problems
have a corresponding trouble code.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and
Inspection > Component Tests and General Diagnostics > Page 3058
Body Controller: Scan Tool Testing and Procedures
If the scan tool Does Not Power Up;
Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link
connector cavity 16).
If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully
charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and
Inspection > Page 3059
Body Controller: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge
- Voltmeter
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > High Altitude Kit - Installation
Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation
NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993
SUBJECT: High Altitude Kits
MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
SYMPTOM/CONDITION:
The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st
page of the Starting and Operating section) that can be used if the owner changes his residence
from an area of low altitude to one of high altitude. These kits are required by the EPA for some
1994 federally certified AS body vehicles to comply with high altitude emissions standards. The
high altitude kit will have no effect on vehicle performance or driveability.
DIAGNOSIS:
Vehicles for which these kits are available have the following statement on the Vehicle Emission
Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE
OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at
the owner's expense.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label.
1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All
Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in
the "Parts Required" section of this bulletin.
2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of
the dash panel that the new labels will be attached to.
3. Attach the new VECI label on top of the original label.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > High Altitude Kit - Installation > Page 3064
4. Type in the required information on the Authorized Modification label (P/N 4275086) as
illustrated, and attach next to the VECI label.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations > Component Locations
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations > Component Locations > Page 3067
Powertrain Control Module (PCM) And Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3070
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3071
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3072
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3073
Powertrain Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3074
Powertrain Control Module 60 Way Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3078
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3079
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3082
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3083
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3084
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3085
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 3086
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 3094
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component
Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component
Locations > Page 3097
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3100
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3101
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3102
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 3103
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3104
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3105
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3106
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3107
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications
Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications
NOTE: For information on how this type of sensor operates SEE, Powertrain
Management/Computers and Control Systems/Coolant Temperature Sensor/Description and
Operation.
NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM).
COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
-20° F ...................................................................................................................................................
....................................... 4.70 V
-10° F ...................................................................................................................................................
....................................... 4.57 V
0° F ......................................................................................................................................................
...................................... 4.45 V
10° F ....................................................................................................................................................
....................................... 4.30 V
20° F ....................................................................................................................................................
....................................... 4.10 V
30° F ....................................................................................................................................................
....................................... 3.90 V
40° F ....................................................................................................................................................
....................................... 3.60 V
50° F ....................................................................................................................................................
....................................... 3.30 V
60° F ....................................................................................................................................................
....................................... 3.00 V
70° F ....................................................................................................................................................
....................................... 2.75 V
80° F ....................................................................................................................................................
....................................... 2.44 V
90° F ....................................................................................................................................................
....................................... 2.15 V
100° F ..................................................................................................................................................
........................................ 1.83 V
110° F ..................................................................................................................................................
........................................ 1.57 V
120° F ..................................................................................................................................................
........................................ 1.25 V
HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm)
Temperature ........................................................................................................................................
........................................ Voltage
110° F ..................................................................................................................................................
........................................ 4.20 V
120° F ..................................................................................................................................................
........................................ 4.00 V
130° F ..................................................................................................................................................
........................................ 3.77 V
140° F ..................................................................................................................................................
........................................ 3.60 V
150° F ..................................................................................................................................................
........................................ 3.40 V
160° F ..................................................................................................................................................
........................................ 3.20 V
170° F ..................................................................................................................................................
........................................ 3.02 V
180° F ..................................................................................................................................................
........................................ 2.80 V
190° F ..................................................................................................................................................
........................................ 2.60 V
200° F ..................................................................................................................................................
........................................ 2.40 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 3112
210° F ..................................................................................................................................................
........................................ 2.20 V
220° F ..................................................................................................................................................
........................................ 2.00 V
230° F ..................................................................................................................................................
........................................ 1.80 V
240° F ..................................................................................................................................................
........................................ 1.62 V
250° F ..................................................................................................................................................
........................................ 1.45 V
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Electrical Specifications > Page 3113
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 3114
Coolant Temperature Sensor/Switch (For Computer): Locations
Ignition Coil And Coolant Temperature Sensor Location
Sensor mounted under ignition coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Diagram Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Diagram Information and Instructions > Page 3117
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Diagram Information and Instructions > Page 3118
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Diagram Information and Instructions > Page 3119
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Diagram Information and Instructions > Page 3120
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Diagram Information and Instructions > Page 3121
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Diagram Information and Instructions > Page 3122
Coolant Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Page 3123
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
LOCATION
The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the
thermostat housing.
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Page 3124
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Coolant Temperature Sensor Resistance Test
1. With key off, disconnect connector from coolant temperature sensor.
2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows;
- 700 to 1,000 Ohms at approximately 200°F (operating temperature).
- 7,000 to 13,000 ohms at approximately 70°F, (room temperature).
3. If resistance is not within specifications, replace sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams > Page 3125
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Ignition Coil And Coolant Temperature Sensor Location
REMOVAL
1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical
connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant
temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6.
Remove sensor from engine.
INSTALLATION
1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor.
3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12
Nm (105 in lbs) torque. 5. Connect electrical connector to coil.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 3130
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component
Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component
Locations > Page 3133
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3136
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3137
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3138
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 3139
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3140
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3141
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3142
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3143
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Vacuum in Inches of Mercury MAP sensor Signal Voltage
.39 in Hg ..............................................................................................................................................
.............................. 4.90 V
3.34 in Hg ............................................................................................................................................
............................... 4.60 V
6.30 in Hg ............................................................................................................................................
............................... 3.60 V
9.25 in Hg ............................................................................................................................................
............................... 3.10 V
12.20 in Hg ..........................................................................................................................................
................................ 2.60 V
15.15 in Hg ..........................................................................................................................................
................................ 2.10 V
18.11 in Hg ..........................................................................................................................................
................................ 1.60 V
21.06 in Hg ..........................................................................................................................................
................................ 1.10 V
24.01 in Hg ..........................................................................................................................................
................................ 0.60 V
26.97 in Hg ..........................................................................................................................................
................................ 0.31 V
Condition .............................................................................................................................................
.................................. Expected Output Voltage
High Vacuum (Idle/Deceleration)
.............................................................................................................................................................
0.5 to 1.5 volts
Medium Vacuum (Cruise/Slight Acceleration)
......................................................................................................................................... 1.5 to 3.0
volts
Low Vacuum (Hard Acceleration/Mechanical Failure)
............................................................................................................................. 3.0 to 4.5 volts
NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Control Component Locations
Back Side Of Intake Plenum View
Sensor mounted on back side of intake plenum.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3149
Back Side Of Intake Plenum View
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3152
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3153
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3154
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3155
Manifold Pressure/Vacuum Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3156
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3157
MAP Sensor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3158
Manifold Pressure/Vacuum Sensor: Description and Operation
LOCATION
Sensor mounted on intake plenum.
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts.
- Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3159
Manifold Pressure/Vacuum Sensor: Testing and Inspection
NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its
circuitry, refer to appropriate Diagnostic Chart. See: Testing and Inspection
TO TEST THE MAP SENSOR ONLY:
1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary.
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition
switch ON, and the engine OFF. Output voltage
should be 4 to 5 volts.
3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle
speed condition. The voltage should drop to 1.5
to 2.1 volts.
4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness
condition. Repair as necessary.
5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage
should be approximately 5 volts (±O.5 V). 5
volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair
or replace the wire harness as necessary.
6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal
/ pin-4. Repair the wire harness if necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3160
Manifold Pressure/Vacuum Sensor: Service and Repair
MAP" Sensor
Removal
1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting
screws and remove sensor.
Installation
1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Oxygen Sensor: Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations
Oxygen Sensor: Component Locations
EGR Mounting
Sensor threaded into exhaust manifold, just above flange.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
3166
Back Side Of Intake Plenum View
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3169
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3170
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3171
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 3172
Oxygen Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3174
Oxygen Sensor: Electrical Diagrams
Oxygen Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3175
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3176
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control
Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control
Module Response Test > Page 3179
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control
Module Response Test > Page 3180
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
Oxygen Sensor And Connector
Oxygen Sensor Connector Identification And PINOUT
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground
(terminals 3 and 4), of the sensor electrical
connector.
3. Resistance should be between 5 and 7 ohms, if not replace the sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 3181
Oxygen Sensor: Service and Repair
Oxygen Sensor Location (Typical)
Oxygen Sensor Socket
WARNING: Avoid physical contact with hot exhaust components.
CAUTION: Do not pull on or cut sensor wires, when removing sensor.
CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL
1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket
YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly
tightening the
sensor before removal may ease removal.)
3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap.
INSTALLATION
1. If a new sensor is being used, verify that the threads are coated with anti-seize compound,
before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel
based anti-seize compound, (Loctite 771-64 or equivalent).
CAUTION: Do not use graphite or other anti-seize compounds.
3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission
Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
3195
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations
> Page 3198
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3201
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3202
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3203
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 3204
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3206
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3207
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3208
Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3209
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3210
Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3219
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 (V6-201 3.3L (1994))
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 3220
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 > 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 3221
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3227
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 (V6-201 3.3L (1994))
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 3228
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3233
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 (V6-201 3.3L (1994))
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 3234
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 (V6-201 3.3L (1994))
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 3235
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3241
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 (V6-201 3.3L (1994))
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 3242
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3245
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3246
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3249
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3252
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3255
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 (V6-201 3.3L (1994))
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 3256
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations
Vehicle Speed Sensor: Component Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations >
Page 3261
Vehicle Speed Sensor: Connector Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3264
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3265
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3266
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 3267
Vehicle Speed Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3268
Vehicle Speed Sensor: Electrical Diagrams
Vehicle Speed Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3269
Vehicle Speed Sensor: Description and Operation
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep >
94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3283
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Component Locations > Page 3286
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3289
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3290
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3291
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3292
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3293
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3294
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Page 3295
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Page 3296
Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Page 3297
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Page 3298
Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3307
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 (V6-201 3.3L (1994))
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 3308
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 (V6-201 3.3L (1994))
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 3309
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
3315
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 (V6-201 3.3L (1994))
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
3316
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
3321
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 (V6-201 3.3L (1994))
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
3322
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 (V6-201 3.3L (1994))
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
3323
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3329
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 (V6-201 3.3L (1994))
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 3330
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
3333
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
3334
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3337
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 3340
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3343
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3344
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Component Locations
Vehicle Speed Sensor: Component Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Component Locations > Page 3349
Vehicle Speed Sensor: Connector Locations
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3352
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3353
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3354
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3355
Vehicle Speed Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3356
Vehicle Speed Sensor: Electrical Diagrams
Vehicle Speed Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Page 3357
Vehicle Speed Sensor: Description and Operation
This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates
vehicle speed based on input received from Input and Output speed sensor mounted on the
transaxle.
Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component
Information > Description and Operation
Voltage Signal: Description and Operation
PURPOSE
Supplies Powertrain Control Module (PCM), with current charging system voltage.
OPERATION
If the PCM senses low battery voltage:
- PCM increases injector pulse width to compensate for low voltage.
- PCM increases generator field voltage.
If the PCM senses high battery voltage:
- PCM decreases injector pulse width to compensate for high voltage.
- PCM decreases generator field voltage.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 110396 > Jun > 96 > Catalytic
Converter - Excessive Sulfur Odor
Catalytic Converter: Customer Interest Catalytic Converter - Excessive Sulfur Odor
NO: 11-03-96
GROUP: Exhaust
EFFECTIVE DATE: June 17, 1996
SUBJECT: Excessive Sulphur Odor
MODELS:
1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994
(AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY.
SYMPTOM/CONDITION:
New catalytic converters are now available to address customer complaints of excessive hydrogen
sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts
were specially manufactured with a revised internal coating which minimizes sulphur odor.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves the replacement of the catalytic converter with a revised part.
Replace the catalytic converter following the repair procedures given in group 11 of the appropriate
service manual.
POLICY: Reimbursable within the provisions of the warranty,
TIME ALLOWANCE:
Labor Operation No: 11-50-01-91 0.7 Hrs.
FAILURE CODE: P8-New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 110396 > Jun > 96 >
Catalytic Converter - Excessive Sulfur Odor
Catalytic Converter: All Technical Service Bulletins Catalytic Converter - Excessive Sulfur Odor
NO: 11-03-96
GROUP: Exhaust
EFFECTIVE DATE: June 17, 1996
SUBJECT: Excessive Sulphur Odor
MODELS:
1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994
(AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY.
SYMPTOM/CONDITION:
New catalytic converters are now available to address customer complaints of excessive hydrogen
sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts
were specially manufactured with a revised internal coating which minimizes sulphur odor.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves the replacement of the catalytic converter with a revised part.
Replace the catalytic converter following the repair procedures given in group 11 of the appropriate
service manual.
POLICY: Reimbursable within the provisions of the warranty,
TIME ALLOWANCE:
Labor Operation No: 11-50-01-91 0.7 Hrs.
FAILURE CODE: P8-New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 3375
Exhaust System - FWD Minivans
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 3376
Catalytic Converter: Description and Operation
Three Way Catalyst (TWC)
PURPOSE
Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and
Oxides of Nitrogen (NOx)), by up to 90%.
OPERATION
Oxidation Reaction
As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation
(burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor
(H2O) and Carbon Dioxide (CO2).
This process no effect on NOx emissions.
Reduction Reaction
The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal
of oxygen), reaction.
OPERATING ENVIRONMENT
A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only
be achieved in a properly functioning feedback system with oxygen sensor.
The ideal converter operating temperature, for maximum emission reduction and long service life
is, 400°C - 800°C (750°F - 1500°F).
Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede
1400°C (2500°F), which can melt substrate material.
CONSTRUCTION
Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately
2 grams of platinum and rhodium).
CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material,
reducing or eliminating catalyst activity.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 3377
Catalytic Converter: Service and Repair
Exhaust System - FWD Minivans
REMOVAL
1. Remove clamp holding muffler to converter.
2. Remove muffler from converter (it may be necessary to heat the pipe connection). 3. Remove
clamp securing converter to header pipe. 4. Remove converter from header pipe (it may be
necessary to heat the pipe connection).
INSTALLATION
1. Install converter to header pipe with a new clamp.
2. Reposition rear exhaust pipe hanger. 3. Install muffler to converter with a new clamp. 4. Start the
engine and inspect for exhaust leaks
NOTE: Replace any missing or damaged heat shields.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Service Reminder Indicator Light <-->
[Emissions Maintenance Light] > Component Information > Description and Operation
Service Reminder Indicator Light: Description and Operation
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 Emission Maintenance Reminder (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. After necessary emission maintenance has been performed, connect Diagnosis
Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by
DRB II tool.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Component Locations
Canister Purge Solenoid: Component Locations
EVAP Canister Location
Duty Cycle Purge Solenoid Location
Solenoid mounted 0n front motor mount, near belts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 3386
Canister Purge Solenoid
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions
Canister Purge Solenoid: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3389
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3390
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3391
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3392
Canister Purge Solenoid: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3393
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3394
Evaporative Solenoid Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3395
Canister Purge Solenoid: Description and Operation
Duty Cycle Purge Solenoid Location
PURPOSE
Powertrain Control Module (PCM) controls timing and rate of purge flow, by varying solenoid pulse
width, (the length of time solenoid is energized per cycle).
OPERATION
PCM controls solenoid by applying and removing solenoid ground. During open loop operation, (including cold start up and hot start time delay), the PCM
DE-ENERGIZES the solenoid, preventing EVAP Canister purge.
- When the engine enters closed loop, (after warm-up and time delay), PCM ENERGIZES and
DE-ENERGIZES solenoid approximately 5 to 10 times per second, depending on operating
conditions.
NOTE: Solenoid will not operate unless installed correctly. The word TOP should face up when
installed.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3396
Canister Purge Solenoid: Testing and Inspection
Canister Purge Solenoid/Charcoal Canister
Evaporative Canister Location
VISUAL INSPECTION
1. Check condition and routing of vacuum hoses. Refer to Vehicle Emission Control Information
(VECI) label, (underhood). 2. Ensure all vacuum hoses and electrical wires are clear of exhaust
manifold to prevent deterioration. Due to temperature, vacuum hoses should
always be a minimum of three inches from exhaust manifold.
NOTE: Use only fuel resistant hoses when servicing evaporative emission control system. EVAP
CANISTER PURGE SOLENOID TEST
1. Disconnect Solenoid electrical connector, and apply vacuum. Using two jumper wires, energize
the solenoid by connecting one of the solenoid
terminals to ground, and the other terminal to battery positive. A "click" should be heard as voltage is applied to terminal.
- Vacuum should hold when voltage is applied, and bleed off when disconnected.
2. Disconnect jumper wires. 3. Measure resistance between Purge Solenoid terminals.
- Resistance should be between 36 and 44 ohms.
4. If solenoid failed any test, replace solenoid. See COMPONENT REPLACEMENT AND REPAIR
PROCEDURES.
SOLENOID CONTROL CIRCUIT TEST
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3397
1. Disconnect vacuum hose from solenoid to throttle body at throttle body and plug nipple. 2.
Connect vacuum pump to open end of hose. 3. Ensure that engine coolant temperature is less than
140° F (60° C). Start engine and allow to idle. 4. Apply 15 in. Hg vacuum and verify that it holds. 5.
Increase engine speed to 3000 rpm, verify vacuum is still held. 6. Allow engine to warm up until the
coolant temperature is above 158° F (70° C). Increase engine speed to 3000 rpm (within three
minutes of
starting the vehicle) apply vacuum. Vacuum should not hold.
7. Let engine return to idle and apply 15 in Hg vacuum. Verify that vacuum holds. 8. Allow engine
to run longer than 3 minutes and increase speed to 3000 rpm. Apply 15 in. Hg vacuum. Verify that
vacuum holds momentarily
then bleeds off.
NOTE: If solenoid fails any test, check connections, and perform actuation test using scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3398
Canister Purge Solenoid: Service and Repair
Duty Cycle Purge Solenoid Location
REMOVAL
1. Remove vacuum hose and electrical connector from solenoid. 2. Depress tab on top of solenoid.
Slide the solenoid down and out of bracket.
INSTALLATION
1. Slide the solenoid into bracket from the bottom. 2. Connect vacuum hose and electrical
connector to solenoid.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Check Valve > Component Information > Description and Operation
Evaporative Check Valve: Description and Operation
Fuel Tank, Filter, And Chassis Line Routing
PURPOSE
Prevents fuel system damage, by venting the system in the event of high internal pressure or
vacuum.
Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions,
see above).
OPERATION
Rollover Operation Prevents fuel from escaping, (through the EVAP System), in the event of
vehicle rollover, the valve will become inverted. In this position the plunger is forced against the
guide plate and raw fuel is prevented from flowing through the valve orifice into the vent tube.
Vents excess pressure or vacuum to the atmosphere when calibrated valve setting is exceeded.
Pressure Relief Operation One way valve allows fuel and vapors to be vented to the EVAP
canister.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations
Evaporative Emission Control Canister: Locations
Evaporative Canister Location
EVAP Canister Location
Mounted inside right front fender, only the top is visible from engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3405
Evaporative Emission Control Canister: Description and Operation
EVAP Canister Operation
PURPOSE
Prevents fuel system damage, by venting the system in the event of high internal pressure or
vacuum.
Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions,
see above).
OPERATION
Under certain conditions, fuel and fuel vapors in the fuel tank expand.
When the volume of the tank is exceded, by vapors or fuel and vapors, the overflow is routed,
through the pressure relief/rollover valve, to the EVAP canister nipple labeled "Fuel Tank".
The vapors are absorbed by the carbon in the canister, and any liquid fuel enters the reservoir in
the bottom of the canister, (to protect the carbon bed above).
The fuel and vapors are stored in the canister, until the engine is started and certain conditions are
met.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3406
Evaporative Emission Control Canister: Testing and Inspection
Canister Purge Solenoid/Charcoal Canister
Evaporative Canister Location
VISUAL INSPECTION
NOTE: If Charcoal Canister is saturated with liquid fuel check for proper Purge Shutoff Switch and
Pressure/Relief Rollover Valve operation.
1. Check condition and routing of vacuum hoses. Refer to Vehicle Emission Control Information
(VECI) label, (underhood). 2. Ensure all vacuum hoses and electrical wires are clear of exhaust
manifold to prevent deterioration. Due to temperature, vacuum hoses should
always be a minimum of three inches from exhaust manifold.
NOTE: Use only fuel resistant hoses when servicing evaporative emission control system. NOTE:
The Charcoal Canister and Purge Shutoff Switch are a combined unit and are not serviced
separately. If the purge switch or cannister is defective the complete assembly must be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3407
Vapor Canister Hose Connections
EVAP CANISTER CONTROL VALVE TEST
1. Disconnect 3/16" vacuum hose from canister and connect a vacuum pump to nipple. 2. Apply 10
inches of vacuum. 3. If valve does not hold vacuum, replace canister.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3408
Evaporative Emission Control Canister: Service and Repair
Evaporative Canister Location
EVAP Canister Location
REMOVAL
1. Remove fuel tubes and vacuum hoses from canister. 2. Remove canister bracket to body bolts.
One bolt must be removed from over right front tire. 3. Remove canister and bracket from body. 4.
Remove canister to bracket bolt and remove canister from bracket.
INSTALLATION
1. Position canister in mounting bracket. 2. Install canister bolt and tighten to 10 Nm (95 in lb). 3.
Position canister and bracket to body and install bolts. 4. Tighten bolts to 10 Nm (95 in lb). 5. Install
fuel tubes and vacuum hoses on canister.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric
EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Locations
Electric EGR Transducer: Locations
EGR Mounting
Electric EGR Transducer (EET)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric
EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Locations > Page 3413
EGR System
Mounted near the throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric
EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation >
Backpressure Transducer Operation
Electric EGR Transducer: Description and Operation Backpressure Transducer Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a
backpressure transducer, in one package. PURPOSE
When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR
valve control nipple, (depending on engine load conditions).
OPERATION
Transducer is supplied ported vacuum through the solenoid.
Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no
vacuum is applied to the EGR valve.
- When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and
maximum vacuum is applied to the EGR valve.
- When exhaust backpressure is present, but not great enough to close the vacuum bleed valve
completely, the vacuum applied to the EGR valve varies with the backpressure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric
EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation >
Backpressure Transducer Operation > Page 3416
Electric EGR Transducer: Description and Operation Electric EGR Transducer (EET)
Vacuum Control Solenoid Valve Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The EET assembly is a vacuum control solenoid and a backpressure transducer, in one
package. PURPOSE
The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the
Electronic EGR Transducer (EET).
OPERATION
Ported vacuum from the throttle body, is supplied to the solenoid valve.
The PCM controls the flow of vacuum between the throttle body and the back pressure transducer,
(through the solenoid ground circuit).
- When the solenoid is energized (grounded), no vacuum is supplied to the transducer.
- When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer.
The solenoid will always be energized (no EGR), under following conditions:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric
EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation >
Backpressure Transducer Operation > Page 3417
- Engine warm-up, (engine coolant temperature below 40 ~F)
- Engine at idle
- Wide Open Throttle (WOT) operation
- Rapid acceleration/deceleration
- During EGR system diagnostic check
NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at
all times, (adversely affecting engine idle and performance).
Backpressure Transducer Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a
backpressure transducer, in one package. PURPOSE
When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR
valve control nipple, (depending on engine load conditions).
OPERATION
Transducer is supplied ported vacuum through the solenoid.
Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no
vacuum is applied to the EGR valve.
- When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and
maximum vacuum is applied to the EGR valve.
- When exhaust backpressure is present, but not great enough to close the vacuum bleed valve
completely, the vacuum applied to the EGR valve
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric
EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation >
Backpressure Transducer Operation > Page 3418
varies with the backpressure.
Diagnostic Check Operation
The solenoid disables the EGR system periodically, to allow the PCM to perform a diagnostic
check.
- During a diagnostic check, (activated only during select engine/driving conditions), the PCM tests
the entire EGR system for failures.
- If the PCM detects an EGR system failure, the Malfunction Indicator Lamp (MIL), (previously
called the Check Engine Lamp), in the instrument panel will be illuminated, indicating that
immediate service is required.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric
EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Page 3419
Electric EGR Transducer: Service and Repair
EGR Mounting
REMOVAL
1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for
any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove
transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for
signs of leakage or cracks.
INSTALLATION
1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install
transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and
electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Locations
EGR Control Valve: Locations
EGR Mounting
Electric EGR Transducer (EET)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Locations > Page 3423
EGR System
Mounted near the throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions
EGR Control Valve: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions >
Page 3426
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions >
Page 3427
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions >
Page 3428
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions >
Page 3429
EGR Control Valve: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions >
Page 3430
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions >
Page 3431
EGR Solenoid Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Description and Operation > Diagnostic Check
Operation
EGR Control Valve: Description and Operation Diagnostic Check Operation
The solenoid disables the EGR system periodically, to allow the PCM to perform a diagnostic
check.
- During a diagnostic check, (activated only during select engine/driving conditions), the PCM tests
the entire EGR system for failures.
- If the PCM detects an EGR system failure, the Malfunction Indicator Lamp (MIL), (previously
called the Check Engine Lamp), in the instrument panel will be illuminated, indicating that
immediate service is required.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Description and Operation > Diagnostic Check
Operation > Page 3434
EGR Control Valve: Description and Operation Vacuum Control Solenoid Valve Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The EET assembly is a vacuum control solenoid and a backpressure transducer, in one
package. PURPOSE
The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the
Electronic EGR Transducer (EET).
OPERATION
Ported vacuum from the throttle body, is supplied to the solenoid valve.
The PCM controls the flow of vacuum between the throttle body and the back pressure transducer,
(through the solenoid ground circuit).
- When the solenoid is energized (grounded), no vacuum is supplied to the transducer.
- When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer.
The solenoid will always be energized (no EGR), under following conditions:
- Engine warm-up, (engine coolant temperature below 40 ~F)
- Engine at idle
- Wide Open Throttle (WOT) operation
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Valve <--> [EGR Control Solenoid] > Component Information > Description and Operation > Diagnostic Check
Operation > Page 3435
- Rapid acceleration/deceleration
- During EGR system diagnostic check
NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at
all times, (adversely affecting engine idle and performance).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Tube > Component Information > Service and Repair
EGR Tube: Service and Repair
Fig 6 EGR Tube
REMOVAL
1. Remove EGR tube attaching bolts from intake and exhaust manifolds (Fig. 6). 2. Clean intake
and exhaust manifold gasket surfaces. Discard old gasket. 3. Check for signs of leakage or
cracked surfaces on either manifolds or tube. Repair or replace as necessary.
INSTALLATION
1. Loosely assemble EGR tube and new gaskets into place on intake and exhaust manifolds. 2.
Tighten mounting bolts to 22 Nm (200 in lb) torque.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Locations
EGR Valve: Locations
EGR Mounting
Valve and transducer, mounted near throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Locations > Page 3442
EGR Valve: Service and Repair
EGR Mounting
REMOVAL
1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for
any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove
transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for
signs of leakage or cracks.
INSTALLATION
1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install
transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and
electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component
Information > Description and Operation
Fillpipe Restrictor: Description and Operation
Fill Pipe Restrictor
PURPOSE
Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter
with lead.
Flapper controls evaporation of fuel during the time the filler cap is removed.
OPERATION
The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted.
INSPECTION
Use dowel gauge to check opening.
Look for; tampering, broken flapper, excessive wear etc..
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations
Positive Crankcase Ventilation Valve: Locations
Back Side Of Intake Plenum View
Mounted on back side of intake plenum.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3450
Positive Crankcase Ventilation Valve: Testing and Inspection
PCV System
NOTE: Perform both checks if there is a problem suspected in the PCV system. With Engine Idling,
Check for Vacuum at Valve
1. Remove PCV valve from rocker cover, a hissing sound should be heard. 2. Place a finger over
the inlet of the valve, a strong vacuum should be felt. 3. Install the PCV valve, then remove
crankcase inlet air cleaner. With engine idling, loosely hold a piece of stiff paper (such as a parts
tag) over the
opening in the rocker arm cover. After allowing about a minute for the crankcase pressure to
reduce, the paper should be drawn against the opening in the rocker arm cover.
4. If the paper is not drawn against the crankcase inlet air cleaner opening with considerable force,
check the PCV valve, the passage in the throttle
body and the PCV hose for restrictions.
With Engine Off, Check for Valve Movement
1. Remove and shake the PCV valve, a rattling noise should be heard, (valve is not stuck).
DIAGNOSIS
- If A strong vacuum is felt and the PCV valve rattles, the system is operating properly and no
further testing is necessary.
- If no vacuum is felt and the PCV valve rattles, then the intake plenum and/or the crankcase vent
hoses need to be cleaned or replaced. (Do not attempt to clean valve).
- If PCV valve does not rattle when shook, replace valve. (Do not attempt to clean valve).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair
Fuel Pressure Release: Service and Repair
Fig 1 Intake Plenum Mounting Bolts
Fuel Pressure Release Procedure - Typical
WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even
when the engine is OFF.
1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3.
Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose,
tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this
hose to
the fuel rail service port. Fuel pressure should bleed off into container.
5. Perform necessary fuel system service procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through
Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable,
inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform
minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES
MINIMUM AIRFLOW TEST IDLE SPEED
ODOMETER READING IDLE SPEED
Less than 1000 miles 525-875 RPM
More than 1000 miles 575-875 RPM
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications > Page 3462
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Specifications > Page 3466
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise
Auxiliary Air Valve (Idle Speed): Technical Service Bulletins Idle Air Control Motor - Whistling Noise
NO.: 14-09-93 Rev.A
GROUP: Fuel
DATE: Nov. 12, 1993
SUBJECT: Idle Air Control Motor Whistle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED
6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION.
MODELS:
** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth
Avenue
1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country**
1993 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
**NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH
1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.**
SYMPTOM/CONDITION:
Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may
be more prevalent when the engine is under a load such as air conditioning or headlamps on. No
whistling can be heard while cruising.
DIAGNOSIS:
**Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for
several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment.
Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away,
perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin
No. 21-01-93 published 1-13-93.**
PARTS REQUIRED:
1 4612673 Idle Air Control Motor
REPAIR PROCEDURE:
This bulletin involves the replacement of the idle air control motor.
1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control
motor.
2. Run the engine at idle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
14-30-23-96 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component
Information > Description and Operation
Fillpipe Restrictor: Description and Operation
Fill Pipe Restrictor
PURPOSE
Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter
with lead.
Flapper controls evaporation of fuel during the time the filler cap is removed.
OPERATION
The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted.
INSPECTION
Use dowel gauge to check opening.
Look for; tampering, broken flapper, excessive wear etc..
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications
Fuel: Specifications
FUEL REQUIREMENTS
The vehicle is designed to meet all emission regulations and provide excellent fuel economy when
using high quality unleaded gasoline having a minimum octane rating of 87.
The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane
of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded
fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline
will further improve performance.
If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful.
However; continued heavy spark knock at high speeds can cause damage and should be corrected
immediately. Engine damage as a result of heavy spark knock operation may not be covered by
the new vehicle warranty.
In addition to using unleaded gasoline with the proper octane rating, those that contain detergents,
corrosion and stability additives are recommended. Using gasoline that has these additives will
help improve fuel economy, reduce emissions, and maintain vehicle performance.
Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you
experience these problems, try another brand of gasoline before considering service for the
vehicle.
ADDITIVES & OXYGENATE BLENDS
Additives - The use of gasoline containing detergents, corrosion and stability additives is
recommended, as these additives will improve fuel economy, reduce emissions, and maintain
vehicle performance.
Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and
stumble. If you experience these problems, try another brand of gasoline before considering
service for the vehicle.
Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However,
continued heavy spark knock at high speeds can cause damage and should be reported to your
dealer immediately.
CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered
by the new vehicle warranty.
GASOLINE/OXYGENATE BLENDS
Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and
90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle.
Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with
unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other
alcohols called cosolvents.
CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result
in starting and driveability problems and damage critical fuel system components. Problems that
are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty.
CLEAN AIR GASOLINE
MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in
those areas of the country where pollution levels are high. These new blends provide a cleaner
burning fuel and some are referred to as reformulated gasoline..
MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent
MTBE. Gasoline blended with MTBE may be used in your vehicle.
ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17
percent ETBE. Gasoline blended with ETBE may be used in your vehicle.
ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active
solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials.
Indiscriminate use of fuel system cleaning agents should be avoided.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Specifications
Fuel Filler Cap: Specifications
Pressure Vent Limit .............................................................................................................................
................................................ 1.5 psi (10 kPa) Vacuum Vent Limit ...................................................
........................................................................................................................ 1.8 in-Hg (6 kPa)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Specifications > Page 3480
Fuel Filler Cap: Description and Operation
The filler cap is also a pressure/vacuum relief valve, which opens whenever pressure in the tank
gets either too low or too high.
Filler cap venting pressures:
- Pressure above 10.9 to 13.45 kPa (1.58 to 1.95 psi)
- Pressure below 0.97 and 2.0 kPa (0.14 and 0.29 psi)
Only filler caps with these specifications may be used as replacements.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Fuel Pressure Release Procedure - Typical
WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even
when the engine is OFF.
1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3.
Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose,
tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this
hose to
the fuel rail service port. Fuel pressure should bleed off into container.
5. Perform necessary fuel system service procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Locations
Fuel Injector: Locations
Fuel Rail Removal And Replacement (Intake Plenum Removed)
The fuel injectors are attached to the fuel rail which mounts to the lower intake manifold under the
air intake plenum.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Locations > Page 3488
Fuel Injector: Description and Operation
Fuel Injector - Cutaway View
PURPOSE
Enables PCM to compensate for varying engine operating conditions by controlling the amount of
fuel injected, precisely.
- Atomizes fuel for more complete combustion.
- Sprays fuel into intake manifold, above intake ports, in an even, conical pattern.
OPERATION
When an injector solenoid is energized, the plunger is retracted, lifting needle valve off seat,
allowing the pressurized fuel to spray into the intake manifold.
When the solenoid is de-energized spring pressure closes valve.
Since the injector nozzle is a fixed size and fuel pressure is regulated (at 48 psi), the amount of fuel
injected changes only when the amount of time the injector is energized per cycle changes. (This
period of time is called "injector pulse width".)
.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Follow purge system manufacturer's instructions for injector purge procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3491
Fuel Injector: Service and Repair Fuel Injector Replacement
Fuel Injector Removed
Fuel Injector Installation
WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always
release fuel pressure before servicing any fuel system component.
REMOVAL
1. Release fuel system pressure. 2. Disconnect the negative battery cable and remove the fuel rail.
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 installation. If the injector is to be re-used, place a
protective
cap over the injector tip, while it is removed.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3492
INSTALLATION
1. Before installing injectors lubricate the O-ring with a drop of engine oil. 2. For each injector,
install injector top into fuel rail cup, and install injector lock clip by sliding open end into injector slot,
and onto the fuel rail cup
side slots.
3. Install injector electrical connectors. 4. Install fuel rail. 5. Using scan tool [1], activate fuel pump
and pressurize system. 6. Check for leaks.
Remarks
[1] Follow scan tool manufacturer's instructions.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Check Valve >
Component Information > Description and Operation
Fuel Pressure Check Valve: Description and Operation
Fuel Tank, Filter, And Chassis Line Routing
PURPOSE
Prevents fuel system damage, by venting the system in the event of high internal pressure or
vacuum.
Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions,
see above).
OPERATION
Rollover Operation Prevents fuel from escaping, (through the EVAP System), in the event of
vehicle rollover, the valve will become inverted. In this position the plunger is forced against the
guide plate and raw fuel is prevented from flowing through the valve orifice into the vent tube.
Vents excess pressure or vacuum to the atmosphere when calibrated valve setting is exceeded.
Pressure Relief Operation One way valve allows fuel and vapors to be vented to the EVAP
canister.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations
Fuel Pressure Regulator: Locations
Fuel Pressure Regulator Installed
The fuel pressure regulator is mounted on the fuel rail.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 3499
Fuel Pressure Regulator: Description and Operation
Fuel Pressure Regulator
PURPOSE
The fuel pressure regulator is used to maintain a constant pressure of 4 psi in the fuel supply
system.
OPERATION
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 to the fuel rail and then flows through the injectors or 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 3500
Fuel Pressure Regulator: Adjustments
No adjustments available for the fuel system pressure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 3501
Fuel Pressure Regulator: Service and Repair
Fuel Pressure Regulator Installed
WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always
release fuel pressure before servicing any fuel system component.
REMOVAL
1. Release fuel system pressure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2.
Remove the fuel pressure regulator vacuum connector. 3. Remove regulator retaining screw and
remove regulator retainer. Position a shop towel under regulator to catch any fuel spilled when
regulator is
removed.
Fuel Pressure Regulator Removal
4. Remove fuel pressure regulator.
INSTALLATION
1. Be sure that the fuel pressure regulator has 2 plastic spacers and that there are 2 O-rings in the
fuel rail before installing the regulator.. Press
regulator into fuel rail. Place retainer with screw over regulator and torque retainer screw to 7 Nm
(60 in-lbs).
2. Connect fuel pressure regulator vacuum hose and negative battery cable. 3. Using scan tool [1],
activate fuel pump and pressurize system. 4. Check for leaks.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 3502
Remarks
[1] Follow scan tool manufacturer's instructions.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Locations
Fuel Pressure Test Port: Locations
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper
> Component Information > Locations
Fuel Pressure Pulsation Damper: Locations
Fuel Rail
The fuel pressure dampener is located on the fuel rail opposite the fuel pressure regulator.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper
> Component Information > Locations > Page 3509
Fuel Pressure Pulsation Damper: Description and Operation
Fuel Pressure Dampener
The fuel pressure dampener, located downstream from the fuel pressure regulator, damps fuel
pressure pulsations at the injectors caused by the opening and closing of the injectors. The
dampener is an internal rubber diaphragm with a pocket of air behind it.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Fuel Pump Relay: Locations
Power Distribution Center (Relay Locations)
Fuel Pump Relay Socket
Fuel pump relay is located in LH side of engine compartment in the power distribution center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3518
Fuel Pump Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded
by the Powertrain Control Module (PCM).
OPERATION
The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM
is receiving reference signals from the distributor pick-up.
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater
element.
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3519
Fuel Pump Relay: Testing and Inspection
NOTE: The relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the component being operated.
- Terminal number 86 is connected to a switched (+) power source.
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations
Fuel Rail: Locations
Fuel Rail Bolt Location (Intake Plenum Removed)
The fuel rail assembly is mounted beneath the intake manifold, on top of the engine. The intake
manifold must be removed to access the fuel rail.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 3523
Fuel Rail: Description and Operation
Fuel Rail
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 and fuel pressure
regulator, and returns to the tank via the fuel return line.
The fuel rail is under constant fuel pressure and fuel pressure release is required prior to servicing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 3524
Fuel Rail: Service and Repair
WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always
release fuel pressure before servicing any fuel system component.
REMOVAL
1. Release fuel system pressure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2.
Disconnect negative battery cable, and remove air cleaner to throttle body hose. 3. Remove throttle
cable. Remove wiring harness from the throttle cable bracket and intake manifold water tube. 4.
Remove Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors from
throttle body. Remove vacuum hose harness
from throttle body, and PCV and brake booster hoses from air intake plenum.
5. Remove wiring connector from charge temperature sensor. Remove EGR tube flange and
vacuum connections from intake plenum. Remove fuel
hoses from fuel rail. See Powertrain Management/Fuel Delivery and Air Induction/Service and
Repair.
Quick Connect Fittings
6. Remove intake plenum to cylinder head strut. Disconnect oxygen sensor connector, Manifold
Absolute Pressure (MAP) sensor connector and
engine ground strap.
7. Remove the Direct Ignition System (DIS) coils and generator to intake manifold bracket bolt.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 3525
Intake Manifold Bolt Location
8. Remove all 4 intake plenum to intake manifold fasteners, and move plenum back over the rear
valve cover. Cover intake manifold ports before
proceeding.
9. Disconnect fuel pressure regulator vacuum harness. Remove fuel tube retainer bracket and fuel
rail attaching bolts.
10. Spread retainer brackets and remove injector wiring clip from the generator bracket.
Fuel Rail Bolt Location (Intake Plenum Removed)
11. Disconnect cam sensor, coolant temperature sensor and engine temperature sensor
connectors. 12. Remove fuel rail, using care to avoid damaging injectors or injector O-rings.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 3526
Fuel Rail Removal
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 22 Nm (200 in-lbs).
3. Install the fuel tube retaining bracket and torque to 4 Nm (35 in-lbs). 4. Connect cam sensor,
coolant temperature sensor and engine temperature sensor. Install injector wiring harness clips to
the generator bracket and
intake manifold water tube.
5. Connect fuel pressure regulator vacuum hose. Remove covering from intake manifold, and clean
surface. 6. Place intake manifold gaskets on lower manifold. Install intake plenum and hand tighten
fasteners. 7. Install the generator bracket to intake manifold bolt, and the cylinder head to intake
manifold strut bolts, (do not torque at this time).
Intake Manifold Bolt Location
8. Torque intake manifold bolts to 28 Nm (250 in-lbs). Follow torque sequence in image above.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 3527
9 Torque generator bracket to intake manifold, and cylinder head to intake manifold bolts to 54 Nm
(40 ft-lbs).
10. Connect ground strap, MAP sensor, charge temperature sensor and oxygen sensor
connectors. 11. Install DIS coils and torque bolts to 12 Nm (105 in-lbs). 12. Connect fuel lines to
fuel rail and torque clamps to 1 Nm (10 in-lbs). Connect vacuum harness to air intake plenum and
fuel pressure regulator. 13. Connect brake booster supply hose to intake plenum and connect PCV
hose to plenum. Connect IAC motor and TPS electrical connectors, and
connect vacuum harness to throttle body.
14. Install throttle cable, and air inlet hose assembly. Connect negative battery cable.
NOTE: ASD and fuel pump relays remain energized for 7 minutes during the following test, unless
the test is stopped or the ignition switch is turned to the OFF position.
15. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto
Shutdown (ASD) Relay", to activate fuel pump and
pressurize system.
16. Check for leaks.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Operation
Fuel Return Line: Description and Operation Fuel Tank/Lines/Filler Operation
Hoses
The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may
be used as replacements.
Fittings and Clamps
There are two ways that the fuel lines are attached to various fuel system components.
- The first way is with a rolled edge type clamp (the purpose of the rolled edge is to prevent the
clamp from cutting the fuel hoses).
Quick Connect Fuel Fitting Assembly
- The second type of fitting is called a Quick-Connect fuel fitting. These fittings consist of internal
O-rings, a metal locking retainer, and a plastic release collar to disconnect the fitting from the fuel
tube.
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. "Unleaded Fuel Only" Labels are
attached at the instrument panel and near the fuel door, 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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Operation > Page 3532
Fuel Return Line: Description and Operation Quick Connect Fuel Fittings Operation
Disassembly
Quick Connect Fuel Fittings
Notes:
Some fuel lines have quick connect fittings, which are designed to speed up the installation and
removal of fuel lines (Fig. 3).
Quick connect fittings consist of a metal casing, a black plastic release ring, a metal locking
retainer, and internal O-rings.
Warning: Fuel system pressure must be released before disconnecting any fuel system
component.
1. Disconnect the negative battery cable.
2. Remove the fuel tank gas cap to release fuel tank pressure.
3. Perform the Fuel System Pressure Release Procedure.
4. Remove any loose dirt from quick connect fittings.
CAUTION: Wrap shop towels around hoses to catch any gasoline spillage.
5. To remove the fuel tube nipple from a quick connect fitting, pull back on the fitting while pushing
in on the plastic ring. To aid in disassembly, an
open end wrench may be used to push the plastic ring in.
6. Cover the quick connector to prevent contamination.
Assembly
1. Inspect the quick connect fitting to ensure the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE
position, due to mushrooming of the release ring or dirt accumulation, the fitting should be
replaced.
CAUTION: The fuel tube nipples must be lubricated with clean 30 weight engine oil prior to
connecting the quick-connect fitting.
2. Lubricate the male end of the fuel tube with 30 weight engine oil.
3. Insert fuel tube nipple into quick connector fitting. When the fuel tube nipple is inserted into the
quick-connect fitting, the shoulder of the nipple is
locked in place by the locking retainer and the internal O-rings seal the tube.
4. Pull back on the quick connect fitting to verify the connection is secure. The tube should be
locked in place. If the connection is not complete,
make sure the black plastic release is not causing the locking retainer to jam in the release
position.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
5. Using a scan tool, activate the ASD relay, to pressurize the fuel system, and check for leaks.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps
Fuel Return Line: Service and Repair Fuel Hoses and Clamps
NOTE: Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use
hoses marked EFM/EFI.
1. Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks.
Replace cracked, scuffed, or swelled hoses. Replace
hoses that rub against other vehicle components or show sign of wear.
2. When installing FUEL hoses:
- Ensure that they are routed away from contact with other vehicle components that could rub
against them and cause failure.
- Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that
rubber hoses are properly routed and avoid heat sources.
- Use only original equipment or equivalent hose clamps, which have rolled edges to prevent the
clamp from cutting the hose. Other types of clamps may cut into the hoses and cause high
pressure fuel leaks. Tighten hose clamps to 1 N-m (10 in lbs) torque.
- For replacement SEE QUICK-CONNECT FITTING REPLACEMENT. See: Service and
Repair/Quick-Connect Fitting Replacement
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps > Page 3535
Fuel Return Line: Service and Repair Quick-Connect Fitting Service
With Retainer Ring Type Fittings
Quick Connect Fitting (Chassis Fuel Tubes)
Quick Connect Fitting Assembly/Disassembly (Chassis Fuel Tubes)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps > Page 3536
Fuel Line Quick Connect Fitting
NOTE: Plastic ring type quick connect fittings are not serviced separately. Do not attempt to repair
damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting
assembly.
Quick Connect Fittings
REMOVAL
1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps > Page 3537
3. Push the fitting toward the component being serviced while pushing the plastic retainer ring into
the fitting. 4. With the ring depressed, pull the fitting from the component. An open-end wrench may
be used to assist in unlocking the fittings. The retainer
should remain on the fitting.
NOTE: The retainer must be pressed squarely into the fitting. If the retainer is cocked it will be
difficult to disconnect fitting.
5. While fuel lines are disconnected, plug the lines so that dirt and foreign particles do not enter the
lines. 6. Inspect the fitting and connector, and replace as needed.
INSTALLATION
NOTE: Before reassembling the Quick-Connect fittings, clean with a lint free cloth and lubricate the
fuel tube nipples with clean engine oil.
CAUTION: Never install quick connect fitting if retainer ring is damaged or stuck in the release
position.
1. Check that the black plastic ring is in the OUT position. If the release ring is stuck in the release
position due to dirt accumulation or mushrooming
of the release ring, the fitting should be replaced.
2. Push the fuel tube into the connector until a click is felt. Check the connection by pulling back
lightly on the fuel tube (15 to 30 lbs). It should
remain inside the connector, locked in place.
With Single TAB Type Fittings
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps > Page 3538
Quick Connect Fitting Assembly/Disassembly (Except Chassis Fuel Tubes)
MANUAL REMOVAL
1. Bend the retainer tabs down. 2. While pulling up on the underside of the retainer tab, push the
legs of the retainer clip away from each other. 3. Raise the pull tab until the hooks on the legs of
the retainer clip clears the fuel tube. 4. Pull fuel tube out of the Quick-Connect fitting. 5. Check the
connector body and retainer for damage. Replace if necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps > Page 3539
Disconnecting Quick Connect Fittings (Screwdriver)
REMOVAL USING SCREWDRIVER
1. Bend the retainer tabs down. 2. Insert a screwdriver between the retainer clips pull tab and the
body of the Quick-Connect fitting. 3. Rotate the screwdriver 90 degrees to lift the retainer clip. 4.
Raise the pull tab while pushing the legs of the retainer clip away from each other. 5. Raise the
retainer clip until the hooks on the legs of the retainer clip clears the fuel tube. 6. Pull fuel tube out
of the Quick-Connect fitting. 7. Check the connector body and retainer for damage. Replace if
necessary.
Quick Connect Fuel Fitting
INSTALLATION
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps > Page 3540
1. Before installing the fuel tube into Quick-Connect fitting, clean the fuel tube and lubricate the
nipple with new engine oil. 2. Push fuel tube into Quick-Connect fitting until the stop on the fuel
tube rests against the back of the Quick-Connect fitting. 3. Push the retainer clip into the slot in the
Quick-Connect fitting until it locks in place. 4. Bend the retainer clip tabs up into their locking
position.
CAUTION: The fuel system remains pressurized after engine has been shut off. Release system
pressure prior to opening system.
WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye
protection, keep open flame away from fuel system components, and prohibit smoking in service
areas.
NOTE: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank
replacement
With Two TAB Type Fittings
NOTE: Fuel injection quick connect fittings are not serviced separately. Do not attempt to repair
damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting
assembly.
REMOVAL
Fuel Line Quick Connect Fitting
Fuel Line Quick Connect Fitting
1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure. 3. Squeeze
retainer tabs together and pull quick connect fitting off fuel tube nipple. The retainer will remain on
fuel tube.
INSTALLATION
1. Using a clean lint free cloth, clean fuel tube nipple and retainer. 2. Using a clean motor oil, lightly
lube nipple and retainer.
CAUTION: Never install quick connect fitting if retainer is damaged or missing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hoses and Clamps > Page 3541
Fuel Line Quick Connect Fitting
3. Push fitting over fuel tube until retainer seats and a click is heard. When the fitting is properly
locked retainer ears will be visible in the windows. 4. Verify connection by pulling on the fuel tube. If
fitting locks in place connection is secure. 5. Using the DRB II select the Automatic Shut Down
(ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain
Management/Computers and Control Systems/Testing and Inspection/Procedures
CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel
pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Locations
Fuel Supply Line: Locations
Fuel Tank Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Locations > Page 3545
Fuel Tank, Filter, And Chassis Line Routing
The fuel tank is located at the rear of the vehicle between the frame rails. The fuel lines, hoses, and
filter are routed along the right hand (passengers) frame rail.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation
Fuel Supply Line: Description and Operation Fuel Tank/Lines/Filler Tube Operation
Hoses
The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may
be used as replacements.
Fittings and Clamps
There are two ways that the fuel lines are attached to various fuel system components.
- The first way is with a rolled edge type clamp (the purpose of the rolled edge is to prevent the
clamp from cutting the fuel hoses).
Quick Connect Fuel Fitting Assembly
- The second type of fitting is called a Quick-Connect fuel fitting. These fittings consist of internal
O-rings, a metal locking retainer, and a plastic release collar to disconnect the fitting from the fuel
tube.
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. "Unleaded Fuel Only" Labels are
attached at the instrument panel and near the fuel door, 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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3548
Fuel Supply Line: Description and Operation Quick-Connect Fitting Operation
Disassembly
Quick Connect Fuel Fittings
Notes:
Some fuel lines have quick connect fittings, which are designed to speed up the installation and
removal of fuel lines (Fig. 3).
Quick connect fittings consist of a metal casing, a black plastic release ring, a metal locking
retainer, and internal O-rings.
Warning: Fuel system pressure must be released before disconnecting any fuel system
component.
1. Disconnect the negative battery cable.
2. Remove the fuel tank gas cap to release fuel tank pressure.
3. Perform the Fuel System Pressure Release Procedure.
4. Remove any loose dirt from quick connect fittings.
CAUTION: Wrap shop towels around hoses to catch any gasoline spillage.
5. To remove the fuel tube nipple from a quick connect fitting, pull back on the fitting while pushing
in on the plastic ring. To aid in disassembly, an
open end wrench may be used to push the plastic ring in.
6. Cover the quick connector to prevent contamination.
Assembly
1. Inspect the quick connect fitting to ensure the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE
position, due to mushrooming of the release ring or dirt accumulation, the fitting should be
replaced.
CAUTION: The fuel tube nipples must be lubricated with clean 30 weight engine oil prior to
connecting the quick-connect fitting.
2. Lubricate the male end of the fuel tube with 30 weight engine oil.
3. Insert fuel tube nipple into quick connector fitting. When the fuel tube nipple is inserted into the
quick-connect fitting, the shoulder of the nipple is
locked in place by the locking retainer and the internal O-rings seal the tube.
4. Pull back on the quick connect fitting to verify the connection is secure. The tube should be
locked in place. If the connection is not complete,
make sure the black plastic release is not causing the locking retainer to jam in the release
position.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
5. Using a scan tool, activate the ASD relay, to pressurize the fuel system, and check for leaks.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3549
Retainer Ring Type Fittings
Quick Connect Fitting (Chassis Fuel Tubes)
Quick Connect Fitting Assembly/Disassembly (Chassis Fuel Tubes)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3550
Fuel Line Quick Connect Fitting
NOTE: Plastic ring type quick connect fittings are not serviced separately. Do not attempt to repair
damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting
assembly.
Quick Connect Fittings
REMOVAL
1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3551
3. Push the fitting toward the component being serviced while pushing the plastic retainer ring into
the fitting. 4. With the ring depressed, pull the fitting from the component. An open-end wrench may
be used to assist in unlocking the fittings. The retainer
should remain on the fitting.
NOTE: The retainer must be pressed squarely into the fitting. If the retainer is cocked it will be
difficult to disconnect fitting.
5. While fuel lines are disconnected, plug the lines so that dirt and foreign particles do not enter the
lines. 6. Inspect the fitting and connector, and replace as needed.
INSTALLATION
NOTE: Before reassembling the Quick-Connect fittings, clean with a lint free cloth and lubricate the
fuel tube nipples with clean engine oil.
CAUTION: Never install quick connect fitting if retainer ring is damaged or stuck in the release
position.
1. Check that the black plastic ring is in the OUT position. If the release ring is stuck in the release
position due to dirt accumulation or mushrooming
of the release ring, the fitting should be replaced.
2. Push the fuel tube into the connector until a click is felt. Check the connection by pulling back
lightly on the fuel tube (15 to 30 lbs). It should
remain inside the connector, locked in place.
Single TAB Type Fittings
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3552
Quick Connect Fitting Assembly/Disassembly (Except Chassis Fuel Tubes)
MANUAL REMOVAL
1. Bend the retainer tabs down. 2. While pulling up on the underside of the retainer tab, push the
legs of the retainer clip away from each other. 3. Raise the pull tab until the hooks on the legs of
the retainer clip clears the fuel tube. 4. Pull fuel tube out of the Quick-Connect fitting. 5. Check the
connector body and retainer for damage. Replace if necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3553
Disconnecting Quick Connect Fittings (Screwdriver)
REMOVAL USING SCREWDRIVER
1. Bend the retainer tabs down. 2. Insert a screwdriver between the retainer clips pull tab and the
body of the Quick-Connect fitting. 3. Rotate the screwdriver 90 degrees to lift the retainer clip. 4.
Raise the pull tab while pushing the legs of the retainer clip away from each other. 5. Raise the
retainer clip until the hooks on the legs of the retainer clip clears the fuel tube. 6. Pull fuel tube out
of the Quick-Connect fitting. 7. Check the connector body and retainer for damage. Replace if
necessary.
Quick Connect Fuel Fitting
INSTALLATION
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3554
1. Before installing the fuel tube into Quick-Connect fitting, clean the fuel tube and lubricate the
nipple with new engine oil. 2. Push fuel tube into Quick-Connect fitting until the stop on the fuel
tube rests against the back of the Quick-Connect fitting. 3. Push the retainer clip into the slot in the
Quick-Connect fitting until it locks in place. 4. Bend the retainer clip tabs up into their locking
position.
CAUTION: The fuel system remains pressurized after engine has been shut off. Release system
pressure prior to opening system.
WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye
protection, keep open flame away from fuel system components, and prohibit smoking in service
areas.
NOTE: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank
replacement
Two TAB Type Fittings
NOTE: Fuel injection quick connect fittings are not serviced separately. Do not attempt to repair
damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting
assembly.
REMOVAL
Fuel Line Quick Connect Fitting
Fuel Line Quick Connect Fitting
1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure. 3. Squeeze
retainer tabs together and pull quick connect fitting off fuel tube nipple. The retainer will remain on
fuel tube.
INSTALLATION
1. Using a clean lint free cloth, clean fuel tube nipple and retainer. 2. Using a clean motor oil, lightly
lube nipple and retainer.
CAUTION: Never install quick connect fitting if retainer is damaged or missing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3555
Fuel Line Quick Connect Fitting
3. Push fitting over fuel tube until retainer seats and a click is heard. When the fitting is properly
locked retainer ears will be visible in the windows. 4. Verify connection by pulling on the fuel tube. If
fitting locks in place connection is secure. 5. Using the DRB II select the Automatic Shut Down
(ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain
Management/Computers and Control Systems/Testing and Inspection/Procedures
CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel
pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Fittings
Fuel Supply Line: Service and Repair Fuel Fittings
Quick Connect Fittings
1. Disconnect the negative battery cable. 2. Remove the gas tank cap to release fuel tank
pressure. 3. Perform fuel system pressure release procedure. See: Fuel Filter/Fuel Pressure
Release/Service and Repair 4. Clean fitting to prevent contamination of the system when the
system is opened. 5. Wrap hoses with shop towels to contain any fuel spray and catch spilled fuel.
6. Push in on the black plastic ring on the end of the fitting and pull the quick connector from the
fuel tube. If more force is needed an open end
wrench may be used to push the plastic ring into the nipple.
7. Cut as little fuel tube on each side of the fitting as is needed to leave clean, undistorted ends. 8.
Discard fitting and hose ends. 9
If it is necessary to replace fuel hose, hose used must be marked EFM/EFI due to higher system
pressure.
10. Replace fittings with the correct size and type fittings. 11. Attach the hoses to the fittings using
"rolled edge" hose clamps only, other types of hose clamps may cut into the fuel hose and cause to
fuel leaks.
Torque hose clamps to 1 Nm (10 in-lbs).
NOTE: ASD and fuel pump relays remain energized for 7 minutes during the following test, unless
the test is stopped or the ignition switch is turned to the OFF position.
12. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto
Shutdown (ASD) Relay", to activate fuel pump and
pressurize system.
13. Check for leaks.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Fittings > Page 3558
Fuel Supply Line: Service and Repair Fuel Hoses and Clamps
NOTE: Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use
hoses marked EFM/EFI.
1. Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks.
Replace cracked, scuffed, or swelled hoses. Replace
hoses that rub against other vehicle components or show sign of wear.
2. When installing FUEL hoses:
- Ensure that they are routed away from contact with other vehicle components that could rub
against them and cause failure.
- Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that
rubber hoses are properly routed and avoid heat sources.
- Use only original equipment or equivalent hose clamps, which have rolled edges to prevent the
clamp from cutting the hose. Other types of clamps may cut into the hoses and cause high
pressure fuel leaks. Tighten hose clamps to 1 N-m (10 in lbs) torque.
- For replacement SEE QUICK-CONNECT FITTING REPLACEMENT. See: Service and
Repair/Quick-Connect Fitting Replacement
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Locations
Fuel Filler Hose: Locations
Fuel Tank Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Locations > Page 3563
Fuel Tank, Filter, And Chassis Line Routing
The fuel tank is located at the rear of the vehicle between the frame rails. The fuel lines, hoses, and
filter are routed along the right hand (passengers) frame rail.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Locations > Page 3564
Fuel Filler Hose: Description and Operation
Hoses
The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may
be used as replacements.
Fittings and Clamps
There are two ways that the fuel lines are attached to various fuel system components.
- The first way is with a rolled edge type clamp (the purpose of the rolled edge is to prevent the
clamp from cutting the fuel hoses).
Quick Connect Fuel Fitting Assembly
- The second type of fitting is called a Quick-Connect fuel fitting. These fittings consist of internal
O-rings, a metal locking retainer, and a plastic release collar to disconnect the fitting from the fuel
tube.
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. "Unleaded Fuel Only" Labels are
attached at the instrument panel and near the fuel door, 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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions
Fuel Gauge Sender: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 3569
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 3570
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 3571
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 3572
Fuel Gauge Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 3573
Fuel Pump System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3574
Fuel Gauge Sender: Description and Operation
Fuel Pump MODULE And Connector TYPICAL
The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the
tank change.
As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or
further away from, the sensor signal terminal.
The further away the sensor pickup is, the higher the resistance across the sensor is.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3575
Fuel Gauge Sender: Testing and Inspection
SENDING UNIT TEST
NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check
the gauge -- check for a defective sending unit, sending unit wiring, or body control module.
Sending units and wiring can be checked by grounding the connector leads at the sending unit.
With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to
read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump
module connector.)
The following procedure tests the resistance of the level sensor. It does not test the sensor circuit.
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fluid level changes.
1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the
ground terminal of the fuel pump module connector. (The
middle terminal and the terminal farthest away from the middle terminal.)
2. Move the float lever to the full position and empty position and note the resistance at both points.
3. Replace the sensor if the resistance is not within the specified values.
- Sensor Full Position 8 ohms maximum
- Sensor Empty Position 96.5 - 108.0 ohms
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3576
Fuel Gauge Sender: Service and Repair
Fuel level sensor replacement procedure is included in Fuel Pump Module service.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Mounting Straps: >
140294 > Feb > 94 > Fuel Pump - High Pitched Noise
Fuel Tank Mounting Straps: Customer Interest Fuel Pump - High Pitched Noise
NO: 14-02-94 GROUP: Fuel System EFFECTIVE DATE: Feb. 11, 1994
SUBJECT: Fuel Pump Noise
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-12-93 DATED JUL. 9,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PARTS INVOLVED AND THE
REPAIR PROCEDURE ARE DIFFERENT. THIS IS A COMPLETE REVISION.
MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO FRONT WHEEL DRIVE VEHICLES.
SYMPTOM/CONDITION:
The fuel pump produces a high pitched noise while running that is objectionable to the customer.
The fuel pump noise will be most noticeable at idle with all accessories turned off. It is normal to be
able to hear the fuel pump running while listening outside of the vehicle or while sitting in the rear of
the vehicle.
DIAGNOSIS:
With all the windows and doors closed, the engine running, and all accessories turned off, listen for
the fuel pump while sitting in the drivers seat. If excessive fuel pump noise is heard, perform the
repair procedure.
PARTS REQUIRED (see illustration)
REPAIR PROCEDURE:
This bulletin involves installing a revised fuel pump, wiring harness (if applicable), fuel tank
isolators and revised fuel tank straps.
1 Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-16, drain and
remove the fuel tank.
2. Inspect the vehicle for presence of isolated fuel tank straps (P/N 4682784). Isolated straps are
painted black and have a rubber pad between the tank and the strap. The old non-isolated straps
are silver in color. If the straps are the new isolated version, verify the fuel pump is P/N 4682761.
Replace all parts that are not the revised design.
3. FUEL PUMP REPLACEMENT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Mounting Straps: >
140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 3585
A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body
harness and discard it.
B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N
4688376) to the body harness.
C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel
pump module.
D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the
revised fuel pump module (P/N 4682761).
4. FUEL TANK ISOLATION COMPONENT INSTALLATION
A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the
floor pan.
B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the
fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was
(refer to the illustration).
C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel
tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts
to 40 ft.lbs. (54 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting
Straps: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise
Fuel Tank Mounting Straps: All Technical Service Bulletins Fuel Pump - High Pitched Noise
NO: 14-02-94 GROUP: Fuel System EFFECTIVE DATE: Feb. 11, 1994
SUBJECT: Fuel Pump Noise
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-12-93 DATED JUL. 9,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PARTS INVOLVED AND THE
REPAIR PROCEDURE ARE DIFFERENT. THIS IS A COMPLETE REVISION.
MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO FRONT WHEEL DRIVE VEHICLES.
SYMPTOM/CONDITION:
The fuel pump produces a high pitched noise while running that is objectionable to the customer.
The fuel pump noise will be most noticeable at idle with all accessories turned off. It is normal to be
able to hear the fuel pump running while listening outside of the vehicle or while sitting in the rear of
the vehicle.
DIAGNOSIS:
With all the windows and doors closed, the engine running, and all accessories turned off, listen for
the fuel pump while sitting in the drivers seat. If excessive fuel pump noise is heard, perform the
repair procedure.
PARTS REQUIRED (see illustration)
REPAIR PROCEDURE:
This bulletin involves installing a revised fuel pump, wiring harness (if applicable), fuel tank
isolators and revised fuel tank straps.
1 Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-16, drain and
remove the fuel tank.
2. Inspect the vehicle for presence of isolated fuel tank straps (P/N 4682784). Isolated straps are
painted black and have a rubber pad between the tank and the strap. The old non-isolated straps
are silver in color. If the straps are the new isolated version, verify the fuel pump is P/N 4682761.
Replace all parts that are not the revised design.
3. FUEL PUMP REPLACEMENT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting
Straps: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 3591
A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body
harness and discard it.
B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N
4688376) to the body harness.
C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel
pump module.
D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the
revised fuel pump module (P/N 4682761).
4. FUEL TANK ISOLATION COMPONENT INSTALLATION
A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the
floor pan.
B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the
fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was
(refer to the illustration).
C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel
tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts
to 40 ft.lbs. (54 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Rollover/Pressure
Relief Valve <--> [Fuel Tank Pressure Release Valve] > Component Information > Locations
Rollover/Pressure Relief Valve: Locations
Fuel Tank Assembly
The pressure relief/rollover valve is located on the top of the tank, next to the fuel pump.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Rollover/Pressure
Relief Valve <--> [Fuel Tank Pressure Release Valve] > Component Information > Locations > Page 3595
Rollover/Pressure Relief Valve: Service and Repair
WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always
release fuel pressure before servicing any fuel system component.
Fuel Tank Assembly
Pressure Relief/Roll Over Valve
REMOVAL
1. Release fuel system pressure. 2. Remove fuel tank. 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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Rollover/Pressure
Relief Valve <--> [Fuel Tank Pressure Release Valve] > Component Information > Locations > Page 3596
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.
3. Install fuel tank.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise
Idle Speed/Throttle Actuator - Electronic: Technical Service Bulletins Idle Air Control Motor Whistling Noise
NO.: 14-09-93 Rev.A
GROUP: Fuel
DATE: Nov. 12, 1993
SUBJECT: Idle Air Control Motor Whistle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED
6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION.
MODELS:
** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth
Avenue
1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country**
1993 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
**NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH
1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.**
SYMPTOM/CONDITION:
Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may
be more prevalent when the engine is under a load such as air conditioning or headlamps on. No
whistling can be heard while cruising.
DIAGNOSIS:
**Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for
several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment.
Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away,
perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin
No. 21-01-93 published 1-13-93.**
PARTS REQUIRED:
1 4612673 Idle Air Control Motor
REPAIR PROCEDURE:
This bulletin involves the replacement of the idle air control motor.
1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control
motor.
2. Run the engine at idle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
14-30-23-96 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 3603
Idle Speed/Throttle Actuator - Electronic: Connector Locations
Throttle Body View With Idle Air Control Motor
- Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions
Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3606
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3607
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3608
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3609
Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3610
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3611
Idle Air Control Motor Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3612
Idle Speed/Throttle Actuator - Electronic: Description and Operation
Throttle Body View With Idle Air Control Motor
LOCATION
Mounted on throttle body.
PURPOSE
Maintains optimum idle speed under varying engine loads.
Prevents deceleration die out.
OPERATION
Powertrain Control Module (PCM) calculates proper idle speed using information from throttle
position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches.
PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body.
Prevents decel die out by increasing air flow when throttle is closed suddenly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3613
Idle Speed/Throttle Actuator - Electronic: Testing and Inspection
NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool.
CAUTION: Proper safety precautions must be taken when testing the IAC motor.
- Set the parking brake and block the drive wheels
- Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust
components
- Provide proper ventilation while operating the engine
- Always return the engine idle speed to normal before disconnecting the exerciser tool.
- Follow scan tool manufacturer's instructions for testing the IAC motor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3614
Idle Speed/Throttle Actuator - Electronic: Service and Repair
Throttle Body View With Idle Air Control Motor
Removal
1. Disconnect the negative battery cable. 2. Disconnect motor wiring connector. 3. Remove motor
mounting screws (2-25 mm long, Torx head screws), and remove motor, (make sure the O-ring is
removed from throttle body).
Idle Air Control (IAC) Motor Installation
Installation
NOTE: If the pintle measures more than 1 in (25 mm), it must be retracted using scan tool [1].
1. Install motor using a new O-ring, and torque mounting screws to 20 in-lbs (2 Nm). 2. Connect
motor wiring connector. 3. Install air cleaner assembly. 4. Connect negative battery cable.
Remarks
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3615
[1] Follow scan tool manufacturer's instructions.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3619
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3620
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3623
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3624
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3625
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3626
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3627
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Power Distribution Center (Relay Locations)
Fuel Pump Relay Socket
Fuel pump relay is located in LH side of engine compartment in the power distribution center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3634
Fuel Pump Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded
by the Powertrain Control Module (PCM).
OPERATION
The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM
is receiving reference signals from the distributor pick-up.
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater
element.
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3635
Fuel Pump Relay: Testing and Inspection
NOTE: The relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the component being operated.
- Terminal number 86 is connected to a switched (+) power source.
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Auto Sutdown Relay
In the Power Distribution Center left side of engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 3639
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 3640
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3643
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3644
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3645
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3646
Automatic Shut Down (ASD) Relay: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Page 3647
Automatic Shut Down (ASD) Relay: Description and Operation
Relay Locations
PURPOSE
Relay supplies battery voltage to the ignition coil and fuel injector(s).
OPERATION
Ignition switch in the START or RUN position, and PCM is receiving reference signals from the
distributor pick-up.
The Powertrain Control Module (PCM) activates the relay (by supplying a ground).
If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM
interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s).
NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through
the same ground circuit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
NOTE: Relay terminal numbers can be found on the bottom of the relay:
TERMINAL IDENTIFICATION
- Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times.
- Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)
position. Terminal number 87 then supplies battery voltage to the components being operated.
- Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN).
- Terminal number 85 is grounded by the PCM.
PROCEDURE
1. Remove relay before testing.
2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at
this time.
4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present
at this time.
5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal
number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
Continuity should now be present between terminals
number 87 and 30. Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 Volt power source.
- If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring
Diagrams for fuel system wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve
<--> [Rollover Valve, Fuel Tank] > Component Information > Locations
Rollover/Pressure Relief Valve: Locations
Fuel Tank Assembly
The pressure relief/rollover valve is located on the top of the tank, next to the fuel pump.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve
<--> [Rollover Valve, Fuel Tank] > Component Information > Locations > Page 3653
Rollover/Pressure Relief Valve: Description and Operation
Fuel Tank, Filter, And Chassis Line Routing
PURPOSE
Prevents fuel system damage, by venting the system in the event of high internal pressure or
vacuum.
Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions,
see above).
OPERATION
Rollover Operation Prevents fuel from escaping, (through the EVAP System), in the event of
vehicle rollover, the valve will become inverted. In this position the plunger is forced against the
guide plate and raw fuel is prevented from flowing through the valve orifice into the vent tube.
Vents excess pressure or vacuum to the atmosphere when calibrated valve setting is exceeded.
Pressure Relief Operation One way valve allows fuel and vapors to be vented to the EVAP
canister.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve
<--> [Rollover Valve, Fuel Tank] > Component Information > Locations > Page 3654
Rollover/Pressure Relief Valve: Service and Repair
WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always
release fuel pressure before servicing any fuel system component.
Fuel Tank Assembly
Pressure Relief/Roll Over Valve
REMOVAL
1. Release fuel system pressure. 2. Remove fuel tank. 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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve
<--> [Rollover Valve, Fuel Tank] > Component Information > Locations > Page 3655
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.
3. Install fuel tank.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Customer
Interest: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Technical
Service Bulletins: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number
81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3675
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3676
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3677
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3678
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3679
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3680
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3681
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3682
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3683
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3684
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3685
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3686
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3687
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3688
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3689
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3690
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3691
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3692
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3693
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3694
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3695
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3696
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3697
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3698
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3699
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously
Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 3704
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor
Diagnosis
Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed
Sensor Diagnosis
NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994
SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis
MODELS: 1993 - 1994
(AA) Spirit/Acclaim/LeBaron Sedan
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1994 (AP) Shadow/Shadow Convertible/Sundance
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS.
DISCUSSION:
Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection
have been and are continuing to be tested. An unusually large number of these wheel speed
sensors are being found to have no defects.
The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles:
The diagnostic manual MUST be followed without exception. No shortcuts should be used during
the diagnostic procedure.
All diagnostic work Must begin with test "1A".
All diagnostic work MUST end with "VER-1A".
Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as
preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications
Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications
NO.: 05-17-93 Rev. A
GROUP: Brakes
DATE: Dec. 22, 1993
SUBJECT: Left Front Wheel Speed Sensor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991-1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE
SYSTEM (ABS).
DISCUSSION:
On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel,
depending upon the model year. The difference between the two parts is the length of the wiring,
and they should not be interchanged.
P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this
part is used on prior model year vehicles the wiring may become damaged.
P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a **
later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to
the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring.
This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts
catalog bulletin is being developed and the parts catalog will be revised at a later date.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3718
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3719
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3720
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3721
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3722
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3723
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3724
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3725
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3726
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3727
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3728
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3729
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3730
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3731
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3732
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3733
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3734
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3735
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3736
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3737
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3738
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3739
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3740
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3741
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions > Page 3742
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > All Other
Service Bulletins for Throttle Position Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 3747
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3756
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page
3759
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3762
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3763
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3764
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 3765
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3766
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3767
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3768
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3769
Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3770
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 3771
Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Testing and Inspection
Throttle Body: Testing and Inspection
Minimum Air Flow Air Metering Fitting
WARNING: Apply parking brake and/or block wheels before performing any engine running test
with the vehicle on the ground.
PRELIMINARY CHECK
1. With vehicle in PARK (A/T) or NEUTRAL (M/T), START the engine, turn all accessories off, and
allow engine to run until the cooling fan cycles
at least once.
2. Remove intake air hose from throttle body. 3. Cover Idle Air Control by pass passage with finger.
- If engine dies, clean throttle body and retest. SEE MAINTENANCE PROCEDURES.
- If engine does not die, proceed with Minimum Air Flow Test.
TEST PROCEDURE
1. Disconnect the 3/16" idle purge hose from the throttle body nipple and cap the 3/16" nipple. 2.
Disconnect PCV valve and attach metered orifice no. C-5004 (or equivalent 0.125 inch orifice) in
the intake manifold PCV nipple. 3. START engine and allow to idle for at least one minute. 4. Using
scan tool [1], access MINIMUM AIRFLOW IDLE SPEED TEST.
- Idle Air Control (IAC) motor should close the bypass passage fully.
- Idle spark advance should become fixed.
5. Compare idle speed on tachometer to specifications below.
- If idle rpm is within range, Minimum Air Flow is set correctly.
- If idle rpm is not within range, clean the throttle body and retest. SEE FUEL AND AIR
INDUCTION/MAINTENANCE PROCEDURES/THROTTLE BODY CLEANING.
- If throttle body has already been cleaned, and idle is not within specifications, the problem is not
caused by the throttle body.
6. Shut engine OFF, remove; metered orifice, timing light and tachometer. 7. Connect PCV hose.
Uncap throttle body purge nipple and connect purge hose.
Remarks:
[1] Follow scan tool manufacturer's instructions for procedures.
ODOMETER READING IDLE SPEED
Less than 1000 miles 525-875 RPM
More than 1000 miles 575-875 RPM
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
WARNINGS: ^ Clean throttle body in a well ventilated area.
^ Wear proper eye protection. ^ Wear rubber or butyl gloves when using parts cleaner. If cleaner
contacts skin, wash thoroughly. ^ Avoid ingesting cleaner.
PURPOSE
The throttle body is designed to have a gap between the throttle plate and the throttle bore, at
closed throttle (idle), for minimum air flow operation.
It is common for deposits to form in the throttle body and intake plenum. Deposits on the throttle
plate, and throttle bore, which reduce the minimum air flow gap, can cause idle and driveability
problems, (stalling at stops, rough or unstable idle), that may or may not set a Diagnostic Trouble
Code (DTC).
EXAMPLE: If the minimum air flow gap is reduced enough by deposits, and the throttle plate is
closed suddenly (deceleration), the Idle Air Control (IAC) motor cannot adjust fast enough to
compensate for the sudden lack of air, and the vehicle stalls.
INSPECTION
Visually inspect the throttle body for cracks, deformation or tampering. Replace throttle body if
there are any signs damage.
CLEANING PROCEDURE
1. Remove the throttle body. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
CAUTION: Do not use harsh abrasives or tank solvent washing to clean the throttle body.
2. While holding the throttle open, spray the entire throttle body bore and throttle plate with suitable
cleaner. 3. Using a soft scuff pad, clean the throttle body bore and throttle blade (front, back and
edges). It is critical that the edges of the throttle blade, and
the portion of the throttle bore that are close to the throttle blade when it is closed, are free of
deposits.
4. Inspect the intake plenum, and clean, if deposits are visible. 5. Install throttle body, and perform
throttle body minimum airflow test. SEE DIAGNOSIS, TESTING AND INSPECTION
PROCEDURES
NOTES: If vehicle is difficult to start after cleaning throttle body, it may be necessary to reset
adaptive memory. SEE Powertrain Management/
Computers and Control Systems/Testing and Inspection/Procedures.
If minimum air flow idle speed is still not within specifications, after cleaning the throttle body, and
the throttle body shows no signs of physical damage, the problem is not caused by the throttle
body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Throttle Body Cleaning > Page 3777
Throttle Body: Service and Repair Throttle Body Replacement
Throttle Body Removal And Replacement
REMOVAL
1. Disconnect negative cable from battery cable. 2. Remove air inlet to throttle body hose clamp. 3.
Remove 2 screws and air inlet resonator.
Fig 102 Throttle Cable Attachment To Throttle Body
4. Remove throttle and the speed control (if equipped) cables from lever and bracket (Fig. 102).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Throttle Body Cleaning > Page 3778
Fig 105 Throttle Body Electrical And Vacuum Connections
5. Disconnect electrical connectors from the idle air control motor and throttle position sensor (TPS)
(Fig. 105). 6. Disconnect vacuum hoses from throttle body. 7. Remove throttle body to intake
manifold attaching nuts. 8. Remove throttle body and gasket.
INSTALLATION
1. Reverse procedure for installation. Tighten throttle body mounting nuts to 25 Nm (225 in lb)
torque.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle
Cable/Linkage] > Component Information > Adjustments
Accelerator Cable: Adjustments
No adjustments available for the throttle cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle
Cable/Linkage] > Component Information > Adjustments > Page 3782
Accelerator Cable: Service and Repair
Throttle Cable Replacement
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not
damage or kink the core wire inside the cable sheathing.
Removal
1. Working from the engine compartment, hold the throttle body throttle lever in the wide open
position. remove the throttle cable from the throttle
body cam.
2. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from
the upper end of the pedal shaft.
3. Remove retainer clip from throttle cable and grommet at dash panel.
4. From the engine compartment. pull the throttle cable out of the dash panel grommet. The
grommet should remain in the dash panel.
5. Remove the throttle cable from throttle bracket by carefully compressing both retaining ears
simultaneously. Then gently pull the throttle cable
from throttle bracket.
Installation
1. From the engine compartment push the housing end fitting into the dash panel grommet.
2. Install the cable housing (throttle body end) into the cable mounting bracket on the engine.
3. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the
upper end of the pedal shaft.
4. At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and
grommet .
5. From the engine compartment, hold the throttle body lever in the wide open position and install
the throttle cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep >
94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts
Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts
Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed
Transmission Shifts
NO: 18-13-94 Rev. A
GROUP: Vehicle Performance
DATE: Sep. 9, 1994
SUBJECT: Harsh, Erratic or Delayed Transmission Shifts
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED
AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
1994 (ES) Chrysler Voyager (Export Only)
1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L
ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected
or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold
soak) and during warm-up.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or 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.
With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data
Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the
throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full
range of travel, full open then full closed, and watch the voltage readings. The voltage change
should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic
voltage change or no voltage change during throttle movement in encountered, particularly when
moving the throttle from wide open to closed throttle, proceed with the following repair.**
PARTS REQUIRED:
1 4759001 Throttle Position Sensor
REPAIR PROCEDURE:
This bulletin involves replacing the throttle position sensor with a revised part.
1. Following the proper procedure, remove and replace the throttle position sensor using the new
sensor, P/N 4759001.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-10-95 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 3796
Throttle Position Sensor: Specifications
THROTTLE POSITION
.................................................................................................................................... INCREASE IN
TPS VOLTAGE
10° Closed Throttle*
....................................................................................................................................................... 0
volts
20° .......................................................................................................................................................
........... 0.38 volts
30° .......................................................................................................................................................
........... 0.75 volts
45° Half Throttle
........................................................................................................................................................
1.31 volts
58° .......................................................................................................................................................
......... 1.80 volts**
75° .......................................................................................................................................................
........ 2.43 volts***
90° Wide Open Throttle
.................................................................................................................................................. 3.00
volts
* At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is
moved from the idle position to the "wide open" position, .
** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide
Open Throttle" (WOT).
*** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the
PCM shuts off fuel injection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Component Locations > Page 3799
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3802
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3803
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3804
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3805
Throttle Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3806
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3807
Throttle Position Sensor: Electrical Diagrams
Throttle Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Page 3808
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the
throttle blade (or throttle opening).
Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts,
(at Wide Open Throttle).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Page 3809
Throttle Position Sensor: Testing and Inspection
NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its
circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic
Charts/Introduction.
PROCEDURE
1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output
terminal.
2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire
of the connector. Check this at idle (throttle
plate closed), and at Wide Open Throttle (WOT).
- At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should
increase gradually as the throttle plate is slowly opened from idle to WOT.
- At wide open throttle, TPS output should be approximately 3.5 volts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Page 3810
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Page 3811
Throttle Position Sensor: Service and Repair
Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor
Throttle Position Sensor Removed
Removal
1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring
connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft.
Installation
1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2.
Connect the TPS wiring connector. 3. Connect the negative battery cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
3.3L, 3.8L Except Code T
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators >
System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Electrical Specifications > Page 3827
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Component Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Component Locations > Page 3830
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3833
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3834
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3835
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3836
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3837
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3838
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3839
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3840
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Electrical Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Electrical Specifications > Page 3845
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Component Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Component Locations > Page 3848
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3851
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3852
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3853
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3854
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3855
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 3856
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Page 3857
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Page 3858
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates
Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates > Page 3867
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates > Page 3868
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At
Low Speed/Speedo. Fluctuates
Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At
Low Speed/Speedo. Fluctuates > Page 3874
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At
Low Speed/Speedo. Fluctuates > Page 3875
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Page 3876
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Page 3877
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
Purpose
Transfer electrical current from the distributor to individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3880
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables
must be released from inside the distributor cap.
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic
converter. Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an
open circuit or other damage.
INSPECTION
Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully
seated, and the nipples and spark plug covers should be in good condition.
Covers should fit tightly on the coil, distributor cap towers and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
RESISTANCE TEST
Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
Remove cable from spark plug.
Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables
must be removed from the spark plugs.
Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside
the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance
shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower
and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all
spark plug cables in same manner.
To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not
remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove
the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the
cable. Also, check for a loose connection at the tower or for a faulty coil.
Inspect coil tower for cracks or carbon tracking.
Secondary Ignition Cable Resistance Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten
minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high
resistance as follows:
SPARK PLUG CABLES
1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not
remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the
ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure
probes make good contact.
Resistance should be within tolerance.
4. If the resistance is not within tolerance, remove cable at cap tower and check the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3881
5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in
same manner.
COIL TO DISTRIBUTOR HIGH TENSION CABLE
1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the
cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of
cable. 4. If resistance is not within tolerance, replace the cable.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Electrical Specifications
Ignition Coil: Electrical Specifications
Resistance @ 70-80°F (21-27°C)
Toyodenso
Primary ................................................................................................................................................
............................................... 0.51-0.61 ohms Secondary .................................................................
................................................................................................................... 11,500-13,500 ohms
Diamond
Primary ................................................................................................................................................
............................................... 0.52-0.63 ohms Secondary .................................................................
................................................................................................................... 11,600-15,800 ohms
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Electrical Specifications > Page 3886
Ignition Coil: Mechanical Specifications
Crankshaft Position sensor screw
.................................................................................................................................................... 12
Nm (105 in lbs) Camshaft Position sensor screw
...................................................................................................................................................... 12
Nm (105 in lbs) Coolant Sensor ..........................................................................................................
.......................................................................... 7 Nm (60 in lbs) Ignition Coil ....................................
................................................................................................................................................ 12 Nm
(105 in lbs) Ignition Switch ...................................................................................................................
................................................................. 2 Nm (17 in lbs) Spark Plugs .............................................
........................................................................................................................................... 28 Nm (20
ft lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Component Locations
Ignition Coil: Component Locations
Ignition Coil And Coolant Temperature Sensor Location
Coil pack mounted on intake manifold, above thermostat housing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Component Locations > Page 3889
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Diagram Information and Instructions
Ignition Coil: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Diagram Information and Instructions > Page 3892
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Diagram Information and Instructions > Page 3893
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Diagram Information and Instructions > Page 3894
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Diagram Information and Instructions > Page 3895
Ignition Coil: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Diagram Information and Instructions > Page 3896
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Diagram Information and Instructions > Page 3897
Ignition Coil Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 3898
Ignition Coil: Description and Operation
Molded Coil
LOCATION
Mounted on the intake plenum, above thermostat housing.
PURPOSE
Steps up primary voltage of 12 Volts to a secondary voltage great enough to arc across the spark
plug gap, and ignite the air fuel mixture, (25,000-35,000 Volts).
OPERATION
The PCM uses the Camshaft and Crankshaft Position (CKP) sensor inputs to determine when to
charge and fire the coils.
The Powertrain Control Module (PCM), Controls Ignition Dwell And Timing Through The Coil
Primary Ground.
Power is supplied to the positive side of coils by the ASD relay.
When the primary windings of a coil are grounded by the PCM, current flow in the windings
generates an electromagnetic field. (Low primary resistance of 0.57-0.7 ohms, allows the PCM to
fully charge each coil in a very short period).
The electromagnetic field is concentrated by the iron core.
When the ground is removed, the concentrated field collapses, inducing high voltage in the
secondary windings.
Secondary Voltage Is Routed To The Spark Plugs Via The Secondary Ignition Cables, (in pairs).
Each coil within the pack is wired to fire two spark plugs at the same time, waste spark system.
(One negative voltage and the other positive.)
- The coil outputs are wired so that when one plug is fired during a compression stroke, the other
plug being fired is on an exhaust stroke, (waste spark system).
- The next time this coil is fired, the plug that was on the exhaust stroke will be on the compression
stroke and the one that was on the compression stroke will be on the exhaust stroke.
CONSTRUCTION
The coil pack consists of three epoxy filled ignition coils molded together in one pack.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 3899
Each coil consists of a primary winding, (2-3 hundred turns of heavy gauge wire), over the
secondary windings, (30-40 thousand turns of light gauge wire), wrapped around a soft iron core,
embedded in an epoxy compound to protect the coil from vibration damage.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 3900
Ignition Coil: Service and Repair
Fig 2 Ignition Coil Removal
REMOVAL
1. Remove spark plug cables from coil (Fig. 2).
- Always twist the spark plug boots to break the seal with the plug and pull straight back on the
boot.
2. Remove ignition coil electrical connector. 3. Remove ignition coil mounting screws. 4. Remove
ignition coil.
INSTALLATION
1. Reverse the above procedure for installation.
- Tighten mounting screws to 12 Nm (105 in lb) torque.
2. Transfer spark plug cables to new coil pack.
- The coil pack towers and cables are numbered with the cylinder identification.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Diagrams > Diagram Information and Instructions
Ignition Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Diagrams > Diagram Information and Instructions > Page 3905
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Diagrams > Diagram Information and Instructions > Page 3906
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Diagrams > Diagram Information and Instructions > Page 3907
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Diagrams > Diagram Information and Instructions > Page 3908
Ignition Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3914
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3915
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3916
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3917
Ignition Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3923
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw
..................................................................................................................................................... 14
Nm (125 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Component Locations
Camshaft Position Sensor: Component Locations
Camshaft Position Sensor Location
The Camshaft Position (CMP) sensor is located on the timing gear cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3926
Camshaft Position Sensor Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3929
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3930
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3931
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3932
Camshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3933
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3934
Camshaft Position Sensor: Electrical Diagrams
Camshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 3935
Camshaft Position Sensor: Description and Operation
Camshaft Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
OPERATION
Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts).
- When a notch aligns with the sensor, voltage spikes high (5.0 volts).
- As a group of notches pass under the sensor, the voltage switches from low (metal) to high
(notch) then back to low.
- The number of notches determine the amount of pulses.
NOTE: If available, an oscilloscope can display the square wave patterns of each timing event.
NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat
spot and notches identify, they do not indicate Top Dead Center (TDC) position.
Camshaft Sprocket
- When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket,
it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate).
- When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder
number # 2 crankshaft timing marks are next.
- After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow.
- One camshaft pulse after the three pulses indicates cylinder # 5.
- The two camshaft pulses after cylinder 5 signals cylinder # 6.
- The PCM can synchronize on cylinders 1 or 4.
NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC
occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the
particular cylinder.
NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be
sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain
Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 3936
Camshaft Position Sensor: Service and Repair
Fig. 7 Camshaft Position Sensor
REMOVAL
1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3.
Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt.
NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal.
4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on
the sensor case, and the O-ring may make removal
difficult.
INSTALLATION
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of
the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor
(Fig. 7).
3. Install sensor in the chain case cover and push sensor down until contact is made with the
camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14
Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from
the accessory belt 6. Install engine mount support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications
Crankshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3941
Crankshaft Position Sensor: Mechanical Specifications
Crankshaft Position sensor screw
................................................................................................................................................ 11.9
Nm (105 in lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Component Locations
Crankshaft Position Sensor: Component Locations
Crank Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3944
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3947
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3948
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3949
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3950
Crankshaft Position Sensor: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3951
Crankshaft Position Sensor Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3952
Crankshaft Position Sensor: Electrical Diagrams
Crankshaft Position Sensor Circuit
Complete System Diagrams
For information regarding diagrams for this system, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Page 3953
Crankshaft Position Sensor: Description and Operation
LOCATION
Mounted in transmission housing, above distance sensor.
PURPOSE
Powertrain Control Module (PCM) uses input to determine basic timing.
OPERATION
Crankshaft Sensor
Driveplate
Sensor reads a series of slots cut in transmission driveplate.
NOTE: The distance between the sensor and torque converter drive plate is critical to system
operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE
COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Page 3954
Crankshaft Position Sensor: Service and Repair
Fig. 5 Crankshaft Position Sensor
Removal
1. Disconnect sensor electrical connector (Fig. 5).
2. Remove sensor retaining bolt.
3. Pull sensor straight up, and out of the transaxle housing.
Installation
Notes:
If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer
from the sensor face completely, before attaching new spacer.
If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new
sensor (Fig. 5).
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate.
2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105
in-lbs) torque.
3. Connect sensor electrical connector.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper
Resistant Ignition Cylinder Addition
Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition
Cylinder Addition
NUMBER: 23-44-94D
GROUP: Body
DATE: Jun. 3, 1994
Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105
DISCUSSION:
A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle
security.
The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a
bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove
the screw.
The 1995 Dakota service manual was completed prior to this information being available to Service
Publications. The vehicles listed as 1994 models only, will have this information already in their
corresponding 1995 service manual.
DESCRIPTION OF CHANGES
Add Tamper Resistant Ignition Key Cylinder Info.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper
Resistant Ignition Cylinder Addition > Page 3960
8D - 37
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper
Resistant Ignition Cylinder Addition > Page 3961
8D - 38
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper
Resistant Ignition Cylinder Addition > Page 3962
8D - 39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper
Resistant Ignition Cylinder Addition > Page 3963
8D - 39A
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap Specifications
Spark Plug: Specifications Gap Specifications
NOTE: 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.
Spark Plug Gap ...................................................................................................................................
............................... 1.2 to 1.3 mm (0.048 to 0.053 in)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap Specifications > Page 3968
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
....................................................... 28 Nm (20 ft-lbs)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3969
Spark Plug: Description and Operation
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for
spark plug diagnosis.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 3972
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 3973
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 3974
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 3975
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 3976
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 3977
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 3978
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
PROCEDURE
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Page 3979
Spark Plug: Adjustments
Setting Spark Plug Electrode Gap
Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the
ground -- center electrode.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Replacement Notes
Spark Plug: Service and Repair Replacement Notes
TIP: Always keep plugs in the order they were removed. Any plug that looks different from other
plugs indicates a problem in that cylinder.
NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and
Inspection/Procedures
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Replacement Notes > Page 3982
Spark Plug: Service and Repair Removal and Installation
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
REMOVAL
1. Spray compressed air around spark plug to prevent foreign material from entering combustion
chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back
in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR:
- Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION
1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 3994
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4000
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 (V6-201 3.3L (1994))
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 4001
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4002
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4007
Torque Converter Clutch Solenoid: Connector Locations
Electrical Connections, 3 Speed Automatic
Automatic Transmission Electrical Connections (4 Speed)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Description and Operation > 3 Speed Transmission
Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission
Transmission Switches (locations)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Description and Operation > 3 Speed Transmission > Page 4010
Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission
Automatic Transmission Electrical Connections (4 Speed)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4021
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 (V6-201 3.3L (1994))
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 4022
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 (V6-201 3.3L (1994))
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 4023
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 4024
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 > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4025
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 (V6-201 3.3L (1994))
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 4026
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 > 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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page
4031
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
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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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page
4032
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
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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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page
4037
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4043
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 (V6-201 3.3L (1994))
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 4044
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 > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 4045
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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Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 4046
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 4047
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 (V6-201 3.3L (1994))
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 4048
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 (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates
Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates > Page 4053
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates > Page 4054
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts
Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts > Page 4059
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor
Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle
Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4071
Power Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4072
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4075
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4076
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4077
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4078
Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4079
Control Module: Connector Views
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4080
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4081
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4082
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4083
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4084
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4085
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4086
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4087
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4088
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4089
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 4090
Transmission Control Schematic
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information > Page 4093
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 (V6-201 3.3L (1994))
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 > General Information > Page 4094
Control Module: Description and Operation Electronic Transmission Controller Operation
LOCATION
The EATX control module is located under the hood, in a potted, die cast aluminum housing with a
sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and output speeds over 140 times a second and
responding to each new reading.
- This provides the precise friction element control needed to make smooth clutch-to-clutch shifts
for all gear changes.
As with most automatic transaxles, all shifts involve releasing one element and applying a different
element.
- In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to
ensure that it does not have excess capacity; the apply element is filled until it begins to make the
speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate
of speed change until the shift is complete.
The key to providing excellent shift quality is precision;
EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the
amount of that slip is typically less than a total of 20 degrees.
LEARNING
To achieve that precision, the EATX control module learns the characteristics of the particular
transaxle that it is controlling.
- It learns the release rate of the releasing element and the apply time of the applying element.
- It also learns the rate at which the apply element builds pressure sufficient to begin making the
speed change.
- This method achieves more precision than would be possible with exacting tolerances. It can also
adapt to any changes that occur with age or environment, for example, altitude, temperature,
engine output, etc.
KICKDOWN SHIFTING
For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate
at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing
element reapplies to maintain that speed until the apply element is filled.
This provides quick response since the engine begins to accelerate immediately and a smooth
torque exchange since the release element can control the rate of torque increase.
This control can make any power train feel more responsive without increasing harshness.
SUMMARY
Adaptive controls respond to input speed changes They compensate for changes in engine or
friction element torque and provide good, consistent shift quality for the life of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4097
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 (V6-201 3.3L (1994))
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 Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Relay > Page 4102
Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay
Transmission Relay Location
The Transmission Relay is located in LH side of engine compartment in the Power Distribution
Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Relay > Page 4103
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4104
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4109
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] >
Component Information > Locations
Overdrive Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] >
Component Information > Locations > Page 4115
Overdrive Off Switch (8 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4127
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 (V6-201 3.3L (1994))
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 4128
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 (V6-201 3.3L (1994))
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 4129
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4135
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 (V6-201 3.3L (1994))
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 4136
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4141
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 (V6-201 3.3L (1994))
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 4142
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 (V6-201 3.3L (1994))
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 4143
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4149
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 (V6-201 3.3L (1994))
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 4150
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4153
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4154
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4157
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4160
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4163
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 (V6-201 3.3L (1994))
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 4164
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4173
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4178
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 (V6-201 3.3L (1994))
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 4179
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 (V6-201 3.3L (1994))
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 4180
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4186
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4191
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 (V6-201 3.3L (1994))
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 4192
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 (V6-201 3.3L (1994))
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 4193
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 (V6-201 3.3L (1994))
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 4194
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Input (Turbine) Speed Sensor Connector > Page 4197
Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Page 4198
Transmission Speed Sensor: Description and Operation
Three pressure switches incorporated in an assembly with the solenoids identify solenoid
application.
Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds.
Position switch indicates manual shift lever position.
Engine speed, throttle position, temperature, etc., are also observed.
- Some of these signals are read directly from the engine control sensors; others are read from a
multiplex circuit with the powertrain control module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Page 4199
Transmission Speed Sensor: Testing and Inspection
INPUT (TURBINE) SPEED SENSOR INSPECTION
1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals 1 and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the input speed sensor.
OUTPUT SPEED SENSOR INSPECTION
1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals I and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the output speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Page 4200
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 180197 >
Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set
PROM - Programmable Read Only Memory: Customer Interest MIL ON - Erroneously, DTC Hex
#2E Set
NO: 18-01-97
GROUP: Vehicle Performance
DATE: Jan. 17, 1997
SUBJECT: Erroneous MIL Illumination With Hex Code $2e - EGR
SYSTEM FAILURE
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-21-95, DATED JUL. 14,
1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THE ENGINE
APPLICATIONS HAVE BEEN REVISED.
MODELS:
1993 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L, 3.3L, OR 3.8L ENGINE
APPLICATION.
SYMPTOM/CONDITION:
1. Erroneous MIL illumination with DTC Hex $2e - EGR SYSTEM FAILURE - in ambient
temperatures below 40° F.
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 other than those listed above are
present, perform the Repair Procedure.
EQUIPMENT REQUIRED:
All Symptoms (Flash Programming)
1 CH6OOO Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
NOTE:
THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST
BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1124 OR HIGHER
MUST BE INSTALLED.
REPAIR PROCEDURE:
This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM)
with new software (calibration changes) for all conditions listed.
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 180197 >
Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set > Page 4212
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRBIII on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 4669020. Attach
the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the Authorized Modification Label and attach the label near
the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-47-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 182295 >
Jul > 95 > PCM - Sag or Hesitation on Cold Start Up
PROM - Programmable Read Only Memory: Customer Interest PCM - Sag or Hesitation on Cold
Start Up
NO: 18-22-95
GROUP: Vehicle Performance
EFFECTIVE DATE: Jul. 14, 1995
SUBJECT: Sag or Hesitation on Cold Start Up Below 20 Degrees Fahrenheit
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-23-94 DATED DEC. 2,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO: 81-699-95054). THE
SYMPTOM/CONDITION HAS BEEN REVISED. ALL REVISIONS ARE MARKED WITH
**ASTERISKS**.
MODELS:
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 - 1995 (AS) Caravan/Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1995 (ES) Chrysler Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) AND
EQUIPPED WITH THE 3.3L OR THE 3.8L ENGINE.
SYMPTOM/CONDITION:
Sag or hesitation during operation in ambient temperatures below **20** degrees fahrenheit, high
humidity, and usually after the vehicle has been sitting overnight. **The Check Engine Light may be
illuminated and Diagnostic Trouble Code (DTC) "EGR SYSTEM FAILURE" may be present.**
DIAGNOSIS:
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 (DTC's) are present, record them on the repair order and repair as
necessary before proceeding further with this bulletin. **If no codes or only DTC "EGR SYSTEM
FAILURE" is present and all systems are functioning correctly, proceed with the following repair. **
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GP1B)
1 CH7015 Engine Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
NOTE:
** THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER AND TIL
CD RELEASE 1085 OR HIGHER MUST BE INSTALLED. **
REPAIR PROCEDURE:
This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM)
with new software (calibrations) **which disables EGR diagnostics below 20 degrees fahrenheit.**
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT
MENU.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 182295 >
Jul > 95 > PCM - Sag or Hesitation on Cold Start Up > Page 4217
5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT
MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" and attach it to the
PCM and cover the label with a clear plastic sticker.
10. Type the necessary information on the Authorized Modification Label and attach the label near
the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-19-42-95
Powertrain Control Module Update 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
180197 > Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set
PROM - Programmable Read Only Memory: All Technical Service Bulletins MIL ON - Erroneously,
DTC Hex #2E Set
NO: 18-01-97
GROUP: Vehicle Performance
DATE: Jan. 17, 1997
SUBJECT: Erroneous MIL Illumination With Hex Code $2e - EGR
SYSTEM FAILURE
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-21-95, DATED JUL. 14,
1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THE ENGINE
APPLICATIONS HAVE BEEN REVISED.
MODELS:
1993 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L, 3.3L, OR 3.8L ENGINE
APPLICATION.
SYMPTOM/CONDITION:
1. Erroneous MIL illumination with DTC Hex $2e - EGR SYSTEM FAILURE - in ambient
temperatures below 40° F.
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 other than those listed above are
present, perform the Repair Procedure.
EQUIPMENT REQUIRED:
All Symptoms (Flash Programming)
1 CH6OOO Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
NOTE:
THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST
BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1124 OR HIGHER
MUST BE INSTALLED.
REPAIR PROCEDURE:
This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM)
with new software (calibration changes) for all conditions listed.
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
180197 > Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set > Page 4223
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRBIII on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 4669020. Attach
the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the Authorized Modification Label and attach the label near
the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-47-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
182295 > Jul > 95 > PCM - Sag or Hesitation on Cold Start Up
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Sag or
Hesitation on Cold Start Up
NO: 18-22-95
GROUP: Vehicle Performance
EFFECTIVE DATE: Jul. 14, 1995
SUBJECT: Sag or Hesitation on Cold Start Up Below 20 Degrees Fahrenheit
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-23-94 DATED DEC. 2,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO: 81-699-95054). THE
SYMPTOM/CONDITION HAS BEEN REVISED. ALL REVISIONS ARE MARKED WITH
**ASTERISKS**.
MODELS:
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 - 1995 (AS) Caravan/Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1995 (ES) Chrysler Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) AND
EQUIPPED WITH THE 3.3L OR THE 3.8L ENGINE.
SYMPTOM/CONDITION:
Sag or hesitation during operation in ambient temperatures below **20** degrees fahrenheit, high
humidity, and usually after the vehicle has been sitting overnight. **The Check Engine Light may be
illuminated and Diagnostic Trouble Code (DTC) "EGR SYSTEM FAILURE" may be present.**
DIAGNOSIS:
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 (DTC's) are present, record them on the repair order and repair as
necessary before proceeding further with this bulletin. **If no codes or only DTC "EGR SYSTEM
FAILURE" is present and all systems are functioning correctly, proceed with the following repair. **
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GP1B)
1 CH7015 Engine Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
NOTE:
** THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER AND TIL
CD RELEASE 1085 OR HIGHER MUST BE INSTALLED. **
REPAIR PROCEDURE:
This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM)
with new software (calibrations) **which disables EGR diagnostics below 20 degrees fahrenheit.**
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT
MENU.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
182295 > Jul > 95 > PCM - Sag or Hesitation on Cold Start Up > Page 4228
5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT
MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" and attach it to the
PCM and cover the label with a clear plastic sticker.
10. Type the necessary information on the Authorized Modification Label and attach the label near
the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-19-42-95
Powertrain Control Module Update 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4240
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4246
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 (V6-201 3.3L (1994))
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 4247
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4248
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4253
Torque Converter Clutch Solenoid: Connector Locations
Electrical Connections, 3 Speed Automatic
Automatic Transmission Electrical Connections (4 Speed)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Description and
Operation > 3 Speed Transmission
Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission
Transmission Switches (locations)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Description and
Operation > 3 Speed Transmission > Page 4256
Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission
Automatic Transmission Electrical Connections (4 Speed)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 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 (V6-201 3.3L (1994))
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: > 211096 > Jul > 96
> A/T - Ratcheting Sound When Coming To Stop > Page 4267
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 (V6-201 3.3L (1994))
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: > 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 (V6-201 3.3L (1994))
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: > 211096
> Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4273
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift
Solenoid: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise
Fuel Tank Mounting Straps: All Technical Service Bulletins Fuel Pump - High Pitched Noise
NO: 14-02-94 GROUP: Fuel System EFFECTIVE DATE: Feb. 11, 1994
SUBJECT: Fuel Pump Noise
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-12-93 DATED JUL. 9,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PARTS INVOLVED AND THE
REPAIR PROCEDURE ARE DIFFERENT. THIS IS A COMPLETE REVISION.
MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO FRONT WHEEL DRIVE VEHICLES.
SYMPTOM/CONDITION:
The fuel pump produces a high pitched noise while running that is objectionable to the customer.
The fuel pump noise will be most noticeable at idle with all accessories turned off. It is normal to be
able to hear the fuel pump running while listening outside of the vehicle or while sitting in the rear of
the vehicle.
DIAGNOSIS:
With all the windows and doors closed, the engine running, and all accessories turned off, listen for
the fuel pump while sitting in the drivers seat. If excessive fuel pump noise is heard, perform the
repair procedure.
PARTS REQUIRED (see illustration)
REPAIR PROCEDURE:
This bulletin involves installing a revised fuel pump, wiring harness (if applicable), fuel tank
isolators and revised fuel tank straps.
1 Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-16, drain and
remove the fuel tank.
2. Inspect the vehicle for presence of isolated fuel tank straps (P/N 4682784). Isolated straps are
painted black and have a rubber pad between the tank and the strap. The old non-isolated straps
are silver in color. If the straps are the new isolated version, verify the fuel pump is P/N 4682761.
Replace all parts that are not the revised design.
3. FUEL PUMP REPLACEMENT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift
Solenoid: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 4279
A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body
harness and discard it.
B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N
4688376) to the body harness.
C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel
pump module.
D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the
revised fuel pump module (P/N 4682761).
4. FUEL TANK ISOLATION COMPONENT INSTALLATION
A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the
floor pan.
B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the
fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was
(refer to the illustration).
C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel
tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts
to 40 ft.lbs. (54 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift
Solenoid: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 4285
A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body
harness and discard it.
B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N
4688376) to the body harness.
C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel
pump module.
D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the
revised fuel pump module (P/N 4682761).
4. FUEL TANK ISOLATION COMPONENT INSTALLATION
A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the
floor pan.
B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the
fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was
(refer to the illustration).
C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All
Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel
tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts
to 40 ft.lbs. (54 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4286
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4287
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4292
Torque Converter Clutch Solenoid: Connector Locations
Electrical Connections, 3 Speed Automatic
Automatic Transmission Electrical Connections (4 Speed)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed
Transmission
Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission
Transmission Switches (locations)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed
Transmission > Page 4295
Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission
Automatic Transmission Electrical Connections (4 Speed)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 213793 > Dec > 93 > A/T Harsh 1-2/2-3 Upshifts & 3-2 Kickdown
Accumulator: Customer Interest A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown
NO.: 21-37-93
GROUP: Transmission
DATE: Dec. 17, 1993
SUBJECT: Transmission Shift Quality Improvement
MODELS:
1990 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
1990 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND 31TH
AUTOMATIC TRANSMISSION BUILT PRIOR TO 1994 MODEL MDH 11-01-XX.
SYMPTOM/CONDITION:
Harsh 2-3 upshifts, 3-2 kickdown, 1-2 upshifts and neutral to reverse shifts.
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with the 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 are present and all systems are functioning correctly, proceed with the
following repair.
Check transaxle fluid level and shift linkage for proper function and operation. If the fluid level is
correct and the linkage is operating correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the kickdown, accumulator, reverse servo cushion springs
and the accumulator piston with revised parts.
1. Following the procedure outlined in the appropriate service manual remove the kickdown spring,
accumulator spring, reverse servo cushion spring and the accumulator piston.
2. Install the revised springs and accumulator piston as outlined in the appropriate Service Manual.
3. When performing the Kickdown Band Adjustment, back off 2-1/4 turns from the set torque.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 213793 > Dec > 93 > A/T Harsh 1-2/2-3 Upshifts & 3-2 Kickdown > Page 4304
Labor Operation No. 21-80-03-90 1.2 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 213793 > Dec >
93 > A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown
Accumulator: All Technical Service Bulletins A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown
NO.: 21-37-93
GROUP: Transmission
DATE: Dec. 17, 1993
SUBJECT: Transmission Shift Quality Improvement
MODELS:
1990 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
1990 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND 31TH
AUTOMATIC TRANSMISSION BUILT PRIOR TO 1994 MODEL MDH 11-01-XX.
SYMPTOM/CONDITION:
Harsh 2-3 upshifts, 3-2 kickdown, 1-2 upshifts and neutral to reverse shifts.
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with the 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 are present and all systems are functioning correctly, proceed with the
following repair.
Check transaxle fluid level and shift linkage for proper function and operation. If the fluid level is
correct and the linkage is operating correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the kickdown, accumulator, reverse servo cushion springs
and the accumulator piston with revised parts.
1. Following the procedure outlined in the appropriate service manual remove the kickdown spring,
accumulator spring, reverse servo cushion spring and the accumulator piston.
2. Install the revised springs and accumulator piston as outlined in the appropriate Service Manual.
3. When performing the Kickdown Band Adjustment, back off 2-1/4 turns from the set torque.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 213793 > Dec >
93 > A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown > Page 4310
Labor Operation No. 21-80-03-90 1.2 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4319
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 (V6-201 3.3L (1994))
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 4320
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 (V6-201 3.3L (1994))
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 4321
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4327
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 (V6-201 3.3L (1994))
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 4328
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 (V6-201 3.3L (1994))
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 4329
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4334
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4335
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4336
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4337
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4346
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 (V6-201 3.3L (1994))
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 4347
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 (V6-201 3.3L (1994))
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 4348
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 (V6-201 3.3L (1994))
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 4349
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 (V6-201 3.3L (1994))
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 4350
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 (V6-201 3.3L (1994))
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 4351
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At
Low Speed/Speedo. Fluctuates
Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At
Low Speed/Speedo. Fluctuates > Page 4356
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At
Low Speed/Speedo. Fluctuates > Page 4357
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts
Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts > Page 4362
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4368
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 (V6-201 3.3L (1994))
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 4369
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 (V6-201 3.3L (1994))
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 4370
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 (V6-201 3.3L (1994))
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 4371
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 (V6-201 3.3L (1994))
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 4372
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 (V6-201 3.3L (1994))
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 4373
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 (V6-201 3.3L (1994))
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: > 080794B > Dec
> 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec
> 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4378
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec
> 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4379
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec
> 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec
> 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4384
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep
> 93 > A/T - (41TE) Pinion Factor Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 110396 > Jun > 96
> Catalytic Converter - Excessive Sulfur Odor
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module > Page 4396
Power Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module > Page 4397
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4400
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4401
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4402
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4403
Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4404
Control Module: Connector Views
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4405
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4406
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4407
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4408
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4409
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4410
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4411
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4412
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4413
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4414
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4415
Transmission Control Schematic
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4418
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4419
Control Module: Description and Operation Electronic Transmission Controller Operation
LOCATION
The EATX control module is located under the hood, in a potted, die cast aluminum housing with a
sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and output speeds over 140 times a second and
responding to each new reading.
- This provides the precise friction element control needed to make smooth clutch-to-clutch shifts
for all gear changes.
As with most automatic transaxles, all shifts involve releasing one element and applying a different
element.
- In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to
ensure that it does not have excess capacity; the apply element is filled until it begins to make the
speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate
of speed change until the shift is complete.
The key to providing excellent shift quality is precision;
EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the
amount of that slip is typically less than a total of 20 degrees.
LEARNING
To achieve that precision, the EATX control module learns the characteristics of the particular
transaxle that it is controlling.
- It learns the release rate of the releasing element and the apply time of the applying element.
- It also learns the rate at which the apply element builds pressure sufficient to begin making the
speed change.
- This method achieves more precision than would be possible with exacting tolerances. It can also
adapt to any changes that occur with age or environment, for example, altitude, temperature,
engine output, etc.
KICKDOWN SHIFTING
For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate
at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing
element reapplies to maintain that speed until the apply element is filled.
This provides quick response since the engine begins to accelerate immediately and a smooth
torque exchange since the release element can control the rate of torque increase.
This control can make any power train feel more responsive without increasing harshness.
SUMMARY
Adaptive controls respond to input speed changes They compensate for changes in engine or
friction element torque and provide good, consistent shift quality for the life of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > General Information > Page 4422
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations > Page 4426
Data Link Connector, A/T: Diagrams
Data Link Connector (8 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations > Page 4427
Data Link Connector (6 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations > Page 4428
CCD Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > A/T - (41TE) Pinion Factor Axle Ratio Values
Differential: Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > Page 4433
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4436
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4437
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4438
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4439
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4440
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4441
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4442
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4443
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4444
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4445
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4446
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4447
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 4448
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4457
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 (V6-201 3.3L (1994))
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 4458
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 (V6-201 3.3L (1994))
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 4459
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts
Fluid - A/T: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts > Page 4464
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift > Page 4470
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > 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 4475
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > 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 4476
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > 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 4477
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T Harsh Gear Engagement/Upshifts/Downshifts
Fluid - A/T: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T Harsh Gear Engagement/Upshifts/Downshifts > Page 4482
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift > Page 4488
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transaxle/Transmission - Automatic
See TSB 21-010-06 4/14/2006
CAPACITY, Initial Refill*: All with transverse engine............................................................................
......................................................................................3.8 Liters 4.0 Quarts
All with longitudinal engine...................................................................................................................
............................................4.2 Liters 4.5 Quarts
*With the engine at operating temperature, shift transmission through all gears. Check fluid level in
PARK and add fluid as needed
1993 Grand Caravan adding or replace, Mopar ATF Plus 4 type 9602.
Initial Refill Capacity
Automatic..............................................................................................................................................
..........................................................................AP‡ CAPACITY, Initial Refill*: All with transverse en
gine.......................................................................................................................................................
...........3.8 Liters 4.0 Quarts
All with longitudinal engine...................................................................................................................
............................................4.2 Liters 4.5 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 only when AP is not available only for "Topping off"
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 4491
Fluid - A/T: Fluid Type Specifications
See TSB 21-010-06 4/14/2006
ATF Plus 4 Type 9602 Oil Type
................................................................................................................................................. Mopar
(R) ATF Plus 4 Type 9602, Or Equivalent.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check > Page 4494
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check > Page 4495
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At
Low Temperature > Page 4504
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At
Low Temperature > Page 4505
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At
Low Temperature > Page 4506
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 21-05-97 >
Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 21-05-97 >
Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 4512
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4517
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 (V6-201 3.3L (1994))
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 4518
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 (V6-201 3.3L (1994))
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 4519
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar >
97 > A/T - 41TE/42LE Shudder During EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar >
97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 4525
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Fluid Drain and Refill > Page 4528
Fluid Filter - A/T: Service and Repair Fluid & Filter Change
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4537
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4538
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4539
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 >
Converter Clutch - Vehicle Shudder on Lock Up > Page 4544
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 >
Converter Clutch - Vehicle Shudder on Lock Up > Page 4545
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 180594 > Apr > 94 > TCC Acceleration Shudder/DTC 38 Set
Fluid Pump: Customer Interest TCC - Acceleration Shudder/DTC 38 Set
NO: 18-05-94
GROUP: Vehicle Performance
DATE: Apr. 8, 1994
SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92)
1993 - 1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated
Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades
(depending on final drive ratio, approximately 28 to 42 MPH).
This shudder condition is generally the result of leakage in the transmission front pump caused by
a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code
38 (Torque Converter Control Out of Range).
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with 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. If Diagnostic Trouble Code 38 is present, proceed to the
repair procedure. If no codes are present and all systems are functioning correctly, proceed with
the following:
A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as
necessary.
B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any
abnormal conditions that could contribute to low frequency vibrations.
C. Road test the vehicle at normal operating temperatures while monitoring transmission
performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic
section, to display converter clutch function and throttle angle. EMCC shudder generally is
encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on
final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the
shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged.
This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal,
or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair
procedure.
PARTS REQUIRED:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 180594 > Apr > 94 > TCC Acceleration Shudder/DTC 38 Set > Page 4550
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.
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 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. Before performing the torque converter clutch break in reset procedure verify that the repair has
corrected the shudder condition. Drive the vehicle under the same conditions that caused the
shudder. If the condition is corrected, go to step four.
NOTE:
SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN
PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and
re-evaluate the items listed.
4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure
listed in the appropriate Service Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS &
1992 - 1993 AY 6.1 Hrs.
1993 - 1994 LH 7.1 Hrs.
21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 4556
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 4557
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 4558
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 4563
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
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 4564
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 180594 > Apr > 94
> TCC - Acceleration Shudder/DTC 38 Set
Fluid Pump: All Technical Service Bulletins TCC - Acceleration Shudder/DTC 38 Set
NO: 18-05-94
GROUP: Vehicle Performance
DATE: Apr. 8, 1994
SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92)
1993 - 1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated
Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades
(depending on final drive ratio, approximately 28 to 42 MPH).
This shudder condition is generally the result of leakage in the transmission front pump caused by
a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code
38 (Torque Converter Control Out of Range).
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with 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. If Diagnostic Trouble Code 38 is present, proceed to the
repair procedure. If no codes are present and all systems are functioning correctly, proceed with
the following:
A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as
necessary.
B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any
abnormal conditions that could contribute to low frequency vibrations.
C. Road test the vehicle at normal operating temperatures while monitoring transmission
performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic
section, to display converter clutch function and throttle angle. EMCC shudder generally is
encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on
final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the
shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged.
This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal,
or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair
procedure.
PARTS REQUIRED:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 180594 > Apr > 94
> TCC - Acceleration Shudder/DTC 38 Set > Page 4569
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.
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 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. Before performing the torque converter clutch break in reset procedure verify that the repair has
corrected the shudder condition. Drive the vehicle under the same conditions that caused the
shudder. If the condition is corrected, go to step four.
NOTE:
SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN
PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and
re-evaluate the items listed.
4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure
listed in the appropriate Service Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS &
1992 - 1993 AY 6.1 Hrs.
1993 - 1994 LH 7.1 Hrs.
21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Page 4570
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T >
Component Information > Service and Repair
Governor: Service and Repair
The governor assembly can be removed for reconditioning or replacement without removing the
transfer gear cover, transfer gear and governor support. To remove governor, drain transmission
fluid and remove transmission oil pan. Remove valve body, unbolt governor from governor support,
then remove governor.
When cleaning or assembling the governor assembly, ensure governor valves move freely in
governor body bores.
1. Remove rear cover attaching bolts and rear cover.
Fig. 5 Transfer Shaft Gear Nut Removal
2. Using tool No. L-4434, or equivalent, remove transfer shaft gear retaining nut, Fig. 5.
Fig. 6 Transfer Shaft Gear Removal
3. Using tool No. L-4407, or equivalent, remove transfer shaft gear and shim, Fig. 6. 4. Remove
governor support retainer, then remove low-reverse band anchor pin. 5. Remove governor
assembly. 6. Remove transfer shaft retainer snap ring, then using tool No. L-4512, or equivalent,
and a puller, remove transfer shaft and retainer assembly. 7. Remove transfer shaft retainer from
shaft. 8. Using a screwdriver, remove oil seal from transfer shaft retainer. 9. Tap new oil seal into
shaft retainer.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T >
Component Information > Service and Repair > Page 4574
10. Reverse procedure to install. Tighten nut and cover retaining bolts to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Override Switch
<--> [Overdrive Switch, A/T] > Component Information > Locations
Overdrive Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Override Switch
<--> [Overdrive Switch, A/T] > Component Information > Locations > Page 4578
Overdrive Off Switch (8 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information > Page 4583
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information > Page 4584
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4594
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 (V6-201 3.3L (1994))
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 4595
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 (V6-201 3.3L (1994))
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 4596
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 (V6-201 3.3L (1994))
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 4597
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 (V6-201 3.3L (1994))
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 4598
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 (V6-201 3.3L (1994))
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 4599
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 (V6-201 3.3L (1994))
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: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4604
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4605
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 >
A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 >
A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4610
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4616
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 (V6-201 3.3L (1994))
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 4617
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 (V6-201 3.3L (1994))
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 4618
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 (V6-201 3.3L (1994))
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 4619
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 (V6-201 3.3L (1994))
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 4620
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 > 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 4621
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 (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4626
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4627
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4632
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4644
Power Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4645
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4648
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4649
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4650
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4651
Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4652
Control Module: Connector Views
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4653
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4654
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4655
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4656
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4657
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4658
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4659
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4660
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4661
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4662
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4663
Transmission Control Schematic
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4666
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4667
Control Module: Description and Operation Electronic Transmission Controller Operation
LOCATION
The EATX control module is located under the hood, in a potted, die cast aluminum housing with a
sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and output speeds over 140 times a second and
responding to each new reading.
- This provides the precise friction element control needed to make smooth clutch-to-clutch shifts
for all gear changes.
As with most automatic transaxles, all shifts involve releasing one element and applying a different
element.
- In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to
ensure that it does not have excess capacity; the apply element is filled until it begins to make the
speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate
of speed change until the shift is complete.
The key to providing excellent shift quality is precision;
EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the
amount of that slip is typically less than a total of 20 degrees.
LEARNING
To achieve that precision, the EATX control module learns the characteristics of the particular
transaxle that it is controlling.
- It learns the release rate of the releasing element and the apply time of the applying element.
- It also learns the rate at which the apply element builds pressure sufficient to begin making the
speed change.
- This method achieves more precision than would be possible with exacting tolerances. It can also
adapt to any changes that occur with age or environment, for example, altitude, temperature,
engine output, etc.
KICKDOWN SHIFTING
For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate
at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing
element reapplies to maintain that speed until the apply element is filled.
This provides quick response since the engine begins to accelerate immediately and a smooth
torque exchange since the release element can control the rate of torque increase.
This control can make any power train feel more responsive without increasing harshness.
SUMMARY
Adaptive controls respond to input speed changes They compensate for changes in engine or
friction element torque and provide good, consistent shift quality for the life of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4670
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 (V6-201 3.3L (1994))
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 Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Relay > Page
4675
Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay
Transmission Relay Location
The Transmission Relay is located in LH side of engine compartment in the Power Distribution
Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Relay > Page
4676
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 4677
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Position Relay, A/T > Component Information > Locations > Component Locations
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4682
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4691
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 (V6-201 3.3L (1994))
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 4692
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 (V6-201 3.3L (1994))
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 4693
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4699
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4704
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 (V6-201 3.3L (1994))
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 4705
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 (V6-201 3.3L (1994))
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 4706
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4712
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 (V6-201 3.3L (1994))
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 4713
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 (V6-201 3.3L (1994))
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 4714
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 (V6-201 3.3L (1994))
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 4715
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 (V6-201 3.3L (1994))
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 4716
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 (V6-201 3.3L (1994))
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 4717
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 (V6-201 3.3L (1994))
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 4718
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 (V6-201 3.3L (1994))
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 4719
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 (V6-201 3.3L (1994))
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 4720
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Page 4721
Seals and Gaskets: Service and Repair
Remove Oil Pump Seal
Install Oil Pump Seal
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations
Overdrive Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 4726
Overdrive Off Switch (8 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4738
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 (V6-201 3.3L (1994))
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 4739
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 (V6-201 3.3L (1994))
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 4740
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4746
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 (V6-201 3.3L (1994))
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 4747
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4752
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 (V6-201 3.3L (1994))
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 4753
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 (V6-201 3.3L (1994))
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 4754
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4760
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 (V6-201 3.3L (1994))
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 4761
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4764
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 4765
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4768
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4771
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4774
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 (V6-201 3.3L (1994))
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 4775
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4784
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4789
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 (V6-201 3.3L (1994))
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 4790
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 (V6-201 3.3L (1994))
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 4791
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4797
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
4802
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 (V6-201 3.3L (1994))
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
4803
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 (V6-201 3.3L (1994))
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
4804
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 (V6-201 3.3L (1994))
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 4805
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector >
Page 4808
Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4809
Transmission Speed Sensor: Description and Operation
Three pressure switches incorporated in an assembly with the solenoids identify solenoid
application.
Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds.
Position switch indicates manual shift lever position.
Engine speed, throttle position, temperature, etc., are also observed.
- Some of these signals are read directly from the engine control sensors; others are read from a
multiplex circuit with the powertrain control module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4810
Transmission Speed Sensor: Testing and Inspection
INPUT (TURBINE) SPEED SENSOR INSPECTION
1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals 1 and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the input speed sensor.
OUTPUT SPEED SENSOR INSPECTION
1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals I and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the output speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4811
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4823
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4829
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > Page 4830
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > Page 4831
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
NOTE: When it is necessary to disassemble linkage cable from levers, plastic grommet retainers
should always be replaced with new grommets.
1. Place gearshift lever in P position, then loosen clamp bolt on gearshift cable bracket. 2. On
column shift models, ensure preload adjustment spring engages fork on transaxle bracket. 3. Pull
the shift lever by hand all the way to the front detent position (P), then tighten lock screw to
specification.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4839
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4840
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Description and Operation > Front Sun Gear Assembly > Page 4845
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve
Cable/Linkage, A/T > Component Information > Adjustments
Throttle Valve Cable/Linkage: Adjustments
THROTTLE CABLE
Fig. 3 Throttle Cable Adjustment
1. Perform adjustment with engine at operating temperature, then loosen cable mounting bracket
lock screw, Fig. 3. 2. Position bracket with both alignment tabs touching transaxle cast surface,
then tighten to specifications. 3. Release cross-lock on the cable assembly by pulling cross-lock
upward. Cable must be free to slide completely toward engine to ensure proper
adjustment.
4. Move transaxle throttle control lever fully clockwise against its internal stop, then press
cross-lock downward into locked position. 5. Test cable operation by moving transaxle throttle lever
forward, then slowly release it to ensure full return.
THROTTLE ROD
1. Ensure engine is at normal operating temperature, then loosen adjustment swivel lock screw.
Swivel must be free to slide along flat end of throttle
rod.
2. Hold transaxle throttle lever firmly toward engine against internal stop and tighten swivel lock
screw to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 180594 > Apr > 94 >
TCC - Acceleration Shudder/DTC 38 Set
Torque Converter: Customer Interest TCC - Acceleration Shudder/DTC 38 Set
NO: 18-05-94
GROUP: Vehicle Performance
DATE: Apr. 8, 1994
SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92)
1993 - 1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated
Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades
(depending on final drive ratio, approximately 28 to 42 MPH).
This shudder condition is generally the result of leakage in the transmission front pump caused by
a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code
38 (Torque Converter Control Out of Range).
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with 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. If Diagnostic Trouble Code 38 is present, proceed to the
repair procedure. If no codes are present and all systems are functioning correctly, proceed with
the following:
A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as
necessary.
B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any
abnormal conditions that could contribute to low frequency vibrations.
C. Road test the vehicle at normal operating temperatures while monitoring transmission
performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic
section, to display converter clutch function and throttle angle. EMCC shudder generally is
encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on
final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the
shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged.
This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal,
or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair
procedure.
PARTS REQUIRED:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 180594 > Apr > 94 >
TCC - Acceleration Shudder/DTC 38 Set > Page 4857
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.
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 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. Before performing the torque converter clutch break in reset procedure verify that the repair has
corrected the shudder condition. Drive the vehicle under the same conditions that caused the
shudder. If the condition is corrected, go to step four.
NOTE:
SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN
PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and
re-evaluate the items listed.
4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure
listed in the appropriate Service Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS &
1992 - 1993 AY 6.1 Hrs.
1993 - 1994 LH 7.1 Hrs.
21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 180594 >
Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set
Torque Converter: All Technical Service Bulletins TCC - Acceleration Shudder/DTC 38 Set
NO: 18-05-94
GROUP: Vehicle Performance
DATE: Apr. 8, 1994
SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92)
1993 - 1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated
Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades
(depending on final drive ratio, approximately 28 to 42 MPH).
This shudder condition is generally the result of leakage in the transmission front pump caused by
a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code
38 (Torque Converter Control Out of Range).
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with 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. If Diagnostic Trouble Code 38 is present, proceed to the
repair procedure. If no codes are present and all systems are functioning correctly, proceed with
the following:
A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as
necessary.
B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any
abnormal conditions that could contribute to low frequency vibrations.
C. Road test the vehicle at normal operating temperatures while monitoring transmission
performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic
section, to display converter clutch function and throttle angle. EMCC shudder generally is
encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on
final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the
shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged.
This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal,
or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair
procedure.
PARTS REQUIRED:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 180594 >
Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set > Page 4863
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.
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 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. Before performing the torque converter clutch break in reset procedure verify that the repair has
corrected the shudder condition. Drive the vehicle under the same conditions that caused the
shudder. If the condition is corrected, go to step four.
NOTE:
SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN
PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and
re-evaluate the items listed.
4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure
listed in the appropriate Service Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS &
1992 - 1993 AY 6.1 Hrs.
1993 - 1994 LH 7.1 Hrs.
21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Page 4864
Torque Converter: Specifications
31TH
Flex plate to torque converter bolts
......................................................................................................................................................... 75
Nm ( 55 ft-lbs )
41TE
Drive plate to torque converter bolts
....................................................................................................................................................... 75
Nm ( 55 ft-lbs )
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Page 4865
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch,
A/T > Component Information > Technical Service Bulletins > A/T - 41TE/42LE Shudder During EMCC Shift
Technical Service Bulletin # 21-05-97 Date: 970314
A/T - 41TE/42LE Shudder During EMCC Shift
NO: 21-05-97
GROUP: Transmission
DATE: Mar. 14, 1997
SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter
Clutch) Shift
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 - 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
1996 - 1997 (NS) Town & Country/Caravan/Voyager
NOTE:
1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING
WITH THIS REPAIR PROCEDURE.
SYMPTOM/CONDITION:
Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter
Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to
4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This
condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle
fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle.
NOTE:
MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES.
DIAGNOSIS:
Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while
accelerating through the gears with light throttle application. Pay particular attention during the
EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is
noticed during the shifts, perform the Repair Procedure.
PARTS REQUIRED:
1 04864505 Filter, 41TE Transaxle
1 04796730 Filter, 42LE Transaxle
AR(1) 06032780 0-Ring, Filter
AR 04798233 Oil, ATF+2 Type 7176 (Qts)
AR(1) 82300234 Sealant, RTV
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-55-01-96 1.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch,
A/T > Component Information > Technical Service Bulletins > A/T - 41TE/42LE Shudder During EMCC Shift > Page 4870
This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and
changing the transaxle fluid a second time.
1. Raise the vehicle on a hoist.
2. Clean the transaxle oil pan area and adjoining surfaces.
3. Loosen the transaxle oil pan and drain the fluid into a suitable container.
4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the
inside of the pan and magnet.
5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper
installation which can lead to delayed garage shifts.
6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n
06032780 as necessary.
7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the
transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to
the transaxle and torque the bolts to 19 Nm (165 in. Lbs.).
8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233
through the transaxle fill tube.
9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the transaxle from park to all gear positions ending
in neutral or park.
10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8
in.) below the ADD mark on the dipstick.
11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range.
12. Drive the vehicle a minimum of 10 miles.
13. Repeat steps 1 through 4.
14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle.
Inspect the filter 0-ring for any damage and replace if necessary.
15. After the transaxle has stopped draining, re-install the filter and 0-ring.
16. Complete re-assembly and filling of the transaxle by following steps 7 through 11.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Component Locations > Page 4875
Torque Converter Clutch Solenoid: Connector Locations
Electrical Connections, 3 Speed Automatic
Automatic Transmission Electrical Connections (4 Speed)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission
Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission
Transmission Switches (locations)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission > Page 4878
Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission
Automatic Transmission Electrical Connections (4 Speed)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4883
Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay
Transmission Relay Location
The Transmission Relay is located in LH side of engine compartment in the Power Distribution
Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4884
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 4885
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Relay, A/T > Component Information > Locations > Component Locations
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Relay, A/T > Component Information > Locations > Component Locations > Page 4893
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4902
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 (V6-201 3.3L (1994))
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 4903
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 (V6-201 3.3L (1994))
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 4904
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
4910
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 (V6-201 3.3L (1994))
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
4911
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
4916
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 (V6-201 3.3L (1994))
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
4917
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 (V6-201 3.3L (1994))
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
4918
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4924
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 (V6-201 3.3L (1994))
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 4925
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
4928
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
4929
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 4932
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4935
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4938
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4939
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4951
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4956
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 (V6-201 3.3L (1994))
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 4957
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 (V6-201 3.3L (1994))
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 4958
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4964
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4969
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 (V6-201 3.3L (1994))
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 4970
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 (V6-201 3.3L (1994))
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 4971
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Page 4972
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4975
Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 4976
Transmission Speed Sensor: Description and Operation
Three pressure switches incorporated in an assembly with the solenoids identify solenoid
application.
Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds.
Position switch indicates manual shift lever position.
Engine speed, throttle position, temperature, etc., are also observed.
- Some of these signals are read directly from the engine control sensors; others are read from a
multiplex circuit with the powertrain control module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 4977
Transmission Speed Sensor: Testing and Inspection
INPUT (TURBINE) SPEED SENSOR INSPECTION
1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals 1 and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the input speed sensor.
OUTPUT SPEED SENSOR INSPECTION
1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals I and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the output speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 4978
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4990
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 (V6-201 3.3L (1994))
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 4991
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 (V6-201 3.3L (1994))
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 4992
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 4998
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 (V6-201 3.3L (1994))
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 4999
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 (V6-201 3.3L (1994))
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 5000
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Locations > Component Locations
A604 (41TE) 4 Speed Transaxle
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Locations > Component Locations > Page 5003
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Diagrams > Transaxle Solenoid Connector
Transaxle Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Diagrams > Transaxle Solenoid Connector > Page 5006
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5009
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5010
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5011
Valve Body: Description and Operation 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
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5012
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5013
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 Switch Valve
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5014
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
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
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5015
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5016
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 (V6-201 3.3L (1994))
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
Removal
Oil Pan Bolts
Oil Pan
Oil Filter
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5019
Valve Body Attaching Bolts
NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise.
Push Park Rollers From Guide Bracket
Remove Valve Body
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5020
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5021
Valve Body: Service and Repair Solenoid Assembly Replacement
REMOVAL
Input Speed Sensor Removed
Remove Sound Cover
Remove Attaching Screws
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5022
Remove Solenoid Assembly
INSTALLATION
To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5023
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5024
2-4 Accumulator Plate
TRS, Manual Shaft, And 2-4 Accumulator
Valve Body Screws
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5025
Valve Body And Transfer Plate
Transfer Plate And Separator Plate
Ball Check Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5026
Springs And Valves Location
Remove Or Install Dual Retainer Plate
TC Limit Valve And Low/Reverse Switch Valve
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing
and Inspection
Clutch Switch: Testing and Inspection
Bosch & Nippondenso Starters
The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal
switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal
released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to
floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully
depressed, replace switch if it fails any test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications
Fluid - Differential: Specifications
TYPE ...................................................................................................................................................
........................................................... 80W-90 GL-5
CAPACITY, Refill:
All with longitudinal engine
..........................................................................................................................................................
0.9 Liters 2.0 Pints
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 5040
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 5041
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 5042
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 5043
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 (V6-201 3.3L (1994))
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
Constant Velocity Joint: Service and Repair Inner CV Joint
Disassembly
Driveshaft assembly should be identified before starting service procedure.
On some models when removing housing from tripod, it may be necessary to hold rollers in place
on trunnion studs to prevent needles and rollers from falling out.
1. Remove boot clamps and pull back boot.
Fig. 9 Tripod Removal From Housing
2. On models with S.S.G. driveshafts, pry wire ring tripod retainer from groove around top of
housing using a suitable flathead screwdriver. Do not
distort or damage retainer ring.
3. On all models, clamp shaft of CV joint housing in a vise. Use protective caps on jaws of vice to
prevent damage to shaft.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5048
Fig. 10 Tripod Removal From Housing
4. With interconnecting shaft on an angle to joint housing, gently pull on shaft until one of tripod
bearings is free of plastic retaining collar. Gently
pull on shaft until all rollers are free of housing.
5. On models with spring and cup, remove spring and cup from joint housing.
Fig. 11 Outer Snap Ring Removal
6. On all models, remove outer snap ring from interconnecting shaft. 7. Remove tripod assembly
from interconnecting shaft by tapping on body of tripod assembly with a suitable brass hammer. Do
not hit outer
bearing when removing assembly from interconnecting shaft.
8. If replacing boot, proceed as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5049
Fig. 12 Inner Tripod Retaining Snap Ring Removal
a. On models with inner tripod snap ring, remove snap ring from interconnecting shaft. b. On all
models, pull boot from interconnecting shaft.
Inspection
Remove grease from assembly and inspect bearing race, tripod components, spring cup, spring
and spherical end of connecting shaft for excessive wear or damage. Inspect boot for pinholes,
cracks or other damage.
Assembly
1. If replacing boot, slide new boot into position over end of interconnecting shaft. 2. On models
with single snap ring tripod retention, install new boot to interconnecting shaft, then the tripod
assembly until it is past ring groove.
Install new snap ring into interconnecting shaft.
3. On models with dual tripod retaining snap rings, install inner tripod snap ring to interconnecting
shaft. 4. On all models, install tripod assembly onto interconnecting shaft, chamfer end down. If
necessary, tap tripod assembly onto interconnecting shaft
using a suitable brass hammer. Do not strike bearing assemblies with hammer.
5. Install outer tripod assembly retaining snap ring to interconnecting shaft. 6. Apply suitable CV
joint grease into housing and boot.
Fig. 13 Spring & Cup Installation
7. On models with internal spring and cup, place spring into housing spring pocket with spring cup
attached to exposed end of spring. Place small
amount of grease on concave surface of spring cup.
8. On all models, clamp stub shaft of housing in a suitable vice with protective caps on jaws.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5050
9. On models with plastic retaining collar, while holding housing on an angle, insert each roller one
at a time into retainer collar until all are seated
and locked into housing.
10. On models with wire retaining ring, slip tripod into housing and install tripod wire retaining ring.
11. On models less plastic collar or wire ring, insert tripod into housing. 12. On all models, position
boot over boot retaining groove in housing. Ensure boot is not dimpled or twisted, if necessary, use
a suitable blunt tool to
pry up edge of boot to allow air pressure to equalize.
13. Place new clamp into position on large end of boot, then using a suitable crimping tool, tighten
clamp into place. 14. Refer to chart below for correct driveshaft length. To achieve an accurate
measurement, slide small end of boot and outer housing onto
interconnecting shaft.
Trans driveshaft side dimension "A"
type mm inch
FWD GKN right 476-486 18.7-19.1
FWD GKN left 184-194 7.2-7.6
AWD GKN right 292-302 11.5-11.9
AWD GKN left 184-194 7.2-7.6
15. Install clamp, then using a suitable crimping tool, tighten clamp into place.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5051
Constant Velocity Joint: Service and Repair Outer CV Joint
Disassembly
Driveshaft assembly should be identified before starting service procedure.
Fig. 6 Driveshaft Components
1. Remove boot clamps, then pull back boot to gain access to joint. 2. Clean grease from joint.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5052
3. Place driveshaft assembly in suitable vise with soft faces and support outer joint.
Fig. 14 Outer CV Joint Removal From Shaft
4. On G.K.N. models, remove outer CV joint from shaft by tapping top of joint body with a suitable
soft hammer. 5. On G.K.N. models, remove circlip from shaft groove and discard. 6. On S.S.G.
units, proceed as follows:
a. Mark position of damper weight, then loosen bolts. b. Slide damper weight and boot towards
inner joint.
Fig. 15 Circlip Retainer In Cross
c. Using suitable circlip pliers, expand and hold circlip, then slide joint from shaft. If necessary tap
top of joint body with a suitable soft hammer.
7. On all models, if boot is to be replaced, slide boot from interconnecting shaft. 8. If constant
velocity joint is operating satisfactorily and grease does not appear contaminated, proceed to
"Assembly" procedure. 9. If constant velocity joint is noisy or badly worn, replace entire unit. Repair
kit will include boot, clamps, circlip and lubricant.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5053
Fig. 16 Outer CV Joint Ball Removal
10. Remove surplus grease and mark relative position of inner cross, cage and housing with a dab
of paint. 11. Hold joint vertically in a soft jawed vise. 12. Press downward on one side of inner race
to tilt cage and remove ball from opposite side. If joint is tight, use a suitable hammer and brass
drift to
tap inner race. Do not strike cage. Repeat this step until all balls have been removed. A
screwdriver may be used to pry balls loose.
13. Tilt cage assembly vertically and position two opposing, elongated cage windows in area
between ball grooves.
Fig. 17 Outer CV Joint Cage & Cross Assembly Removal
14. Remove cage and inner race assembly by pulling upward from housing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5054
Fig. 18 Outer CV Joiont Cross Removal From Cage
15. Rotate inner cross 0.0° to cage and align a race spherical land with an elongated cage window.
Raise land into cage window and remove inner race
cross by swinging outward.
Inspection
1. Check housing ball races for excessive wear. 2. Check splined shaft and nut threads for
damage. 3. Inspect balls for pitting, cracks, scouring and wearing. Dulling of surface is normal. 4.
Inspect cage for excessive wear on inner and outer spherical surfaces, heavy brinnelling of cage,
and window cracks and chipping. 5. Inspect inner race (cross) for excessive wear or scoring of ball
races. 6. If any defects are found, replace 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.
7. Inspect boots for pinholes, cracks or other damage.
Assembly
1. 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. 19 Inner CV Joint Cross Installation Into Cage
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5055
3. Align an inner race (cross) land into cage window, then insert race into cage and pivot 90°.
Fig. 20 Outer CV Joint Cage & Cross Assembly Installation Into Housing
4. Align opposing elongated cage windows with housing land and insert cage assembly into
housing. Pivot cage 90° to complete installation.
Fig. 21 Cage & Cross Assembled
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5056
Fig. 22 Cage & Cross Installed In Housing
When properly assembled, large counterbore in cross should be facing outward from joint on
G.K.N. joint.
Fig. 23 Cage & Cross Assembled
On S.S.G. joint, internal clip in cross will be facing outward from housing.
5. Apply suitable lubricant to ball races between all sides of ball grooves. 6. Insert balls into
raceway by tilting cage and inner race assembly. 7. Slide small end of boot over shaft, then place
clamp over groove on boot.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page 5057
Fig. 24 Outer CV Joint Circlip Installation
8. On G.K.N. joint, insert new circlip in shaft groove. Do not over expand or twist circlip during
assembly. 9. On S.S.G. unit, install reusable circlip.
10. On all models, position joint housing on shaft, then engage by tapping sharply with a suitable
soft faced mallet. 11. Ensure snap ring is properly seated by attempting to pull joint from shaft. 12.
Position boot over boot groove in housing, then install clamp.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Adjustments
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel.
3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay
should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter
pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 5063
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 5064
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 5065
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 5066
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 5067
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 5068
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 5069
Wheel Bearing: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front
Wheel Hub: Service and Repair Front
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front > Page 5074
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front > Page 5075
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front > Page 5076
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front > Page 5077
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front > Page 5078
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front > Page 5079
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Front > Page 5080
Wheel Hub: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
31TH
Flex plate to crankshaft bolts ...............................................................................................................
.................................................... 95 Nm ( 70 ft-lbs )
41TE
Drive plate to crankshft bolts ...............................................................................................................
................................................... 95 Nm ( 70 ft-lbs )
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 212493 > Sep > 93 > M/T - Vent Oil Leak
Case: Customer Interest M/T - Vent Oil Leak
NO.: 21-24-93 GROUP: Transmission DATE: Sep. 3, 1993
SUBJECT: Oil Leak At Transaxle Vent
MODELS:
1990 - 1993 (AG) Daytona
1990 - 1994 (AA) Spirit/Acclaim (AJ) LeBaron Coupe/LeBaron Convertible (AP) Shadow/Shadow
Convertible/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH MANUAL TRANSAXLE MODELS
A-523, A-543, OR A-568.
SYMPTOM/CONDITION:
Transaxle oil leak on or around selector shaft cover and/or other surrounding surfaces, including
the rear end cover and differential bearing retainer. Oil found to be leaking out of vent cap on
crossover lever.
NOTE:
THIS REPAIR SHOULD BE PREFORMED ON ALL VEHICLES WITH A VENT LEAK. CUSTOMER
VEHICLES THAT ARE IN THE DEALERSHIP FOR ANY OTHER REASON SHOULD ALSO BE
INSPECTED FOR THIS LEAK CONDITION.
PARTS REQUIRED:
1 Vent Adapter 4762499
1 Vent 4505557
REPAIR PROCEDURE:
This bulletin involves installing a remote vent assembly in place of the existing lock pin. Also
included is a new linkage adjusting procedure if needed for future transaxle service.
1. Clean any excess oil from surrounding surfaces.
2. Remove, lock pin located on transaxle selector shaft cover (Figure 1). Discard lock pin.
3. Install vent adapter (P/N 4762499) in selector shaft cover where lock pin was removed. Tighten
to 40 in.lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 212493 > Sep > 93 > M/T - Vent Oil Leak > Page
5093
4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs.
NOTE:
IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING
PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN.
1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the
vehicle interior as outlined in the appropriate service manual.
2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure
2).
3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift
lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION:
DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE
ADJUSTING SCREW.
4. Reinstall all hardware removed in Step 1.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs.
FAILURE CODE: 71 - Oil Leak
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 212493 > Sep > 93 > M/T - Vent Oil
Leak
Case: All Technical Service Bulletins M/T - Vent Oil Leak
NO.: 21-24-93 GROUP: Transmission DATE: Sep. 3, 1993
SUBJECT: Oil Leak At Transaxle Vent
MODELS:
1990 - 1993 (AG) Daytona
1990 - 1994 (AA) Spirit/Acclaim (AJ) LeBaron Coupe/LeBaron Convertible (AP) Shadow/Shadow
Convertible/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH MANUAL TRANSAXLE MODELS
A-523, A-543, OR A-568.
SYMPTOM/CONDITION:
Transaxle oil leak on or around selector shaft cover and/or other surrounding surfaces, including
the rear end cover and differential bearing retainer. Oil found to be leaking out of vent cap on
crossover lever.
NOTE:
THIS REPAIR SHOULD BE PREFORMED ON ALL VEHICLES WITH A VENT LEAK. CUSTOMER
VEHICLES THAT ARE IN THE DEALERSHIP FOR ANY OTHER REASON SHOULD ALSO BE
INSPECTED FOR THIS LEAK CONDITION.
PARTS REQUIRED:
1 Vent Adapter 4762499
1 Vent 4505557
REPAIR PROCEDURE:
This bulletin involves installing a remote vent assembly in place of the existing lock pin. Also
included is a new linkage adjusting procedure if needed for future transaxle service.
1. Clean any excess oil from surrounding surfaces.
2. Remove, lock pin located on transaxle selector shaft cover (Figure 1). Discard lock pin.
3. Install vent adapter (P/N 4762499) in selector shaft cover where lock pin was removed. Tighten
to 40 in.lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 212493 > Sep > 93 > M/T - Vent Oil
Leak > Page 5099
4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs.
NOTE:
IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING
PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN.
1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the
vehicle interior as outlined in the appropriate service manual.
2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure
2).
3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift
lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION:
DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE
ADJUSTING SCREW.
4. Reinstall all hardware removed in Step 1.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs.
FAILURE CODE: 71 - Oil Leak
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 210994 > Jun > 94 > M/T - Shifter Squeak
When Shifting
Shifter M/T: Customer Interest M/T - Shifter Squeak When Shifting
NO: 21-09-94
GROUP: Transmission
EFFECTIVE DATE: Jun. 10 1994
SUBJECT: Shifter Squeak - Manual Transmission
MODELS:
1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1994 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION.
DISCUSSION:
A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the
select shift cable attaches to the gear shift lever.
DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE.
PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE
ISOLATOR.
If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined
in the appropriate service manual. The correct part numbers for the shifter assembly are listed
below:
4670218 AP and AA Vehicles
4670219 AS Vehicles
4670220 PL Vehicles
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 210994 > Jun > 94 > M/T Shifter Squeak When Shifting
Shifter M/T: All Technical Service Bulletins M/T - Shifter Squeak When Shifting
NO: 21-09-94
GROUP: Transmission
EFFECTIVE DATE: Jun. 10 1994
SUBJECT: Shifter Squeak - Manual Transmission
MODELS:
1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1994 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION.
DISCUSSION:
A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the
select shift cable attaches to the gear shift lever.
DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE.
PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE
ISOLATOR.
If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined
in the appropriate service manual. The correct part numbers for the shifter assembly are listed
below:
4670218 AP and AA Vehicles
4670219 AS Vehicles
4670220 PL Vehicles
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift
Cable, M/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 210994 > Jun >
94 > M/T - Shifter Squeak When Shifting
Shift Cable: Customer Interest M/T - Shifter Squeak When Shifting
NO: 21-09-94
GROUP: Transmission
EFFECTIVE DATE: Jun. 10 1994
SUBJECT: Shifter Squeak - Manual Transmission
MODELS:
1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1994 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION.
DISCUSSION:
A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the
select shift cable attaches to the gear shift lever.
DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE.
PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE
ISOLATOR.
If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined
in the appropriate service manual. The correct part numbers for the shifter assembly are listed
below:
4670218 AP and AA Vehicles
4670219 AS Vehicles
4670220 PL Vehicles
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift
Cable, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: >
210994 > Jun > 94 > M/T - Shifter Squeak When Shifting
Shift Cable: All Technical Service Bulletins M/T - Shifter Squeak When Shifting
NO: 21-09-94
GROUP: Transmission
EFFECTIVE DATE: Jun. 10 1994
SUBJECT: Shifter Squeak - Manual Transmission
MODELS:
1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1994 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION.
DISCUSSION:
A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the
select shift cable attaches to the gear shift lever.
DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE.
PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE
ISOLATOR.
If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined
in the appropriate service manual. The correct part numbers for the shifter assembly are listed
below:
4670218 AP and AA Vehicles
4670219 AS Vehicles
4670220 PL Vehicles
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5137
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 (V6-201 3.3L (1994))
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 5138
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 > 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 5139
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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182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5140
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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and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5141
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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and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5142
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 (V6-201 3.3L (1994))
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: >
080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
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and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5147
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
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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: >
080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5148
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: >
213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
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and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 5153
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
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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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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 5159
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 (V6-201 3.3L (1994))
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 5160
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 (V6-201 3.3L (1994))
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 5161
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 (V6-201 3.3L (1994))
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 5162
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 (V6-201 3.3L (1994))
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 5163
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 (V6-201 3.3L (1994))
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 5164
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 (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5169
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5170
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 5175
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
5187
Power Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
5188
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5191
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5192
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5193
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5194
Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5195
Control Module: Connector Views
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5196
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5197
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5198
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5199
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5200
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5201
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5202
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5203
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5204
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5205
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5206
Transmission Control Schematic
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information >
Page 5209
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 (V6-201 3.3L (1994))
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 > General Information >
Page 5210
Control Module: Description and Operation Electronic Transmission Controller Operation
LOCATION
The EATX control module is located under the hood, in a potted, die cast aluminum housing with a
sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and output speeds over 140 times a second and
responding to each new reading.
- This provides the precise friction element control needed to make smooth clutch-to-clutch shifts
for all gear changes.
As with most automatic transaxles, all shifts involve releasing one element and applying a different
element.
- In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to
ensure that it does not have excess capacity; the apply element is filled until it begins to make the
speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate
of speed change until the shift is complete.
The key to providing excellent shift quality is precision;
EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the
amount of that slip is typically less than a total of 20 degrees.
LEARNING
To achieve that precision, the EATX control module learns the characteristics of the particular
transaxle that it is controlling.
- It learns the release rate of the releasing element and the apply time of the applying element.
- It also learns the rate at which the apply element builds pressure sufficient to begin making the
speed change.
- This method achieves more precision than would be possible with exacting tolerances. It can also
adapt to any changes that occur with age or environment, for example, altitude, temperature,
engine output, etc.
KICKDOWN SHIFTING
For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate
at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing
element reapplies to maintain that speed until the apply element is filled.
This provides quick response since the engine begins to accelerate immediately and a smooth
torque exchange since the release element can control the rate of torque increase.
This control can make any power train feel more responsive without increasing harshness.
SUMMARY
Adaptive controls respond to input speed changes They compensate for changes in engine or
friction element torque and provide good, consistent shift quality for the life of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Page
5213
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.
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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
Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Relay > Page 5218
Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay
Transmission Relay Location
The Transmission Relay is located in LH side of engine compartment in the Power Distribution
Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Relay > Page 5219
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5220
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5225
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations
Overdrive Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page
5231
Overdrive Off Switch (8 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5243
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.
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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 > Page 5244
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 (V6-201 3.3L (1994))
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 5245
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5251
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 (V6-201 3.3L (1994))
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 5252
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5257
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 (V6-201 3.3L (1994))
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 5258
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 (V6-201 3.3L (1994))
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 5259
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5265
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 (V6-201 3.3L (1994))
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 5266
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5269
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5270
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5273
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5276
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5279
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 (V6-201 3.3L (1994))
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 5280
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5289
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
5294
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 (V6-201 3.3L (1994))
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
5295
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 (V6-201 3.3L (1994))
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
5296
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5302
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5307
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 (V6-201 3.3L (1994))
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 5308
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 (V6-201 3.3L (1994))
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 5309
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 (V6-201 3.3L (1994))
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 5310
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed
Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed
Sensor Connector > Page 5313
Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5314
Transmission Speed Sensor: Description and Operation
Three pressure switches incorporated in an assembly with the solenoids identify solenoid
application.
Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds.
Position switch indicates manual shift lever position.
Engine speed, throttle position, temperature, etc., are also observed.
- Some of these signals are read directly from the engine control sensors; others are read from a
multiplex circuit with the powertrain control module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5315
Transmission Speed Sensor: Testing and Inspection
INPUT (TURBINE) SPEED SENSOR INSPECTION
1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals 1 and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the input speed sensor.
OUTPUT SPEED SENSOR INSPECTION
1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals I and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the output speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5316
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions
Transfer Case: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5324
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5325
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5326
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5327
Transfer Case: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5328
Transfer Case: Electrical Diagrams
Transmission Control & AWD System (Part 1 Of 5)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5329
Transmission Control & AWD System (Part 2 Of 5)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5330
Transmission Control & AWD System (Part 3 Of 5)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5331
Transmission Control & AWD System (Part 4 Of 5)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram
Information and Instructions > Page 5332
Transmission Control & AWD System (Part 5 Of 5)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5344
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5350
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 (V6-201 3.3L (1994))
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 5351
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5352
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5357
Torque Converter Clutch Solenoid: Connector Locations
Electrical Connections, 3 Speed Automatic
Automatic Transmission Electrical Connections (4 Speed)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Description and Operation > 3 Speed Transmission
Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission
Transmission Switches (locations)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Description and Operation > 3 Speed Transmission > Page 5360
Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission
Automatic Transmission Electrical Connections (4 Speed)
PURPOSE
The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up
torque converter.
OPERATION
The lock-up torque converter is only locked up when the transmission is in direct drive mode.
If the PCM 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 PCM will disengage
the part throttle solenoid causing the lock-up torque converter to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5371
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 (V6-201 3.3L (1994))
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 5372
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 (V6-201 3.3L (1994))
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 5373
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 5374
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 (V6-201 3.3L (1994))
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 5375
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 (V6-201 3.3L (1994))
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 5376
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 (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page
5381
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page
5382
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts
Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page
5387
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 5393
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 (V6-201 3.3L (1994))
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 5394
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 > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 5395
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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Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 5396
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 (V6-201 3.3L (1994))
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 5397
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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Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 5398
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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates
Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
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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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates > Page 5403
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
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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: > 080794B > Dec > 94 > A/T - Harsh Shift At Low
Speed/Speedo. Fluctuates > Page 5404
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts
Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts
NO.: 21-36-93
GROUP: Transmission
DATE: Dec. 10, 1993
SUBJECT: Improved Transmission Shift Schedule
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH
09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION.
SYMPTOM/CONDITION:
Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1
kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary
Neutral/Drive garage shifts. Park to Reverse noise (grunt).
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 are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4686478 Transmission Control Module
AR 4467721 Transmission Fluid - ATF Plus (7176)
REPAIR PROCEDURE:
This repair involves the replacement of the transmission control module with a module that
incorporates revised software, changing the transmission fluid, setting the pinion factor, and
transaxle quick learn.
1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is
currently installed on the vehicle. This is accomplished by choosing the TSB option under
Adjustments.
NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS
INSPECTED AT THE RETURN CENTER.
2. Replace the transmission control module with the new module, following the procedures outlined
in the appropriate service manual.
3. Change the transmission fluid following the procedure outlined in the service manual.
NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION
FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and
then place gear selector in Neutral.
5. Using the procedures listed in the service manual complete the following: a.
Quick Learn Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 213693 > Dec > 93 > A/T - Harsh Gear
Engagement/Upshifts/Downshifts > Page 5409
b. Electronic Pinion Factor Procedure
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-06-90 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor
Axle Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle
Ratio Values
Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values
NO.: 08-39-93 Rev. A
GROUP: Electrical
DATE: Sep. 17, 1993
SUBJECT: 41TE Pinion Factor Axle Ratio Values
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**
MODELS:
**1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1993 (AY) Imperial/New Yorker Fifth Avenue **
DISCUSSION:
When installing a replacement TCM (Transmission Control Module), it is necessary to set the
pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic
Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the
speedometer indicates correctly.
One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the
correct axle ratios for the various applications:
YEAR ENGINE SIZE RATIO
1993 3.8L 3.19
3.0L and 3.3L 3.62
1994 3.8L 3.45
3.0L and 3.3L 3.62
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5421
Power Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5422
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5425
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5426
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5427
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5428
Control Module: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5429
Control Module: Connector Views
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5430
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5431
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5432
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5433
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5434
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5435
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5436
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5437
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5438
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5439
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > Diagrams >
Diagram Information and Instructions > Page 5440
Transmission Control Schematic
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 > General Information > Page 5443
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 (V6-201 3.3L (1994))
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 > General Information > Page 5444
Control Module: Description and Operation Electronic Transmission Controller Operation
LOCATION
The EATX control module is located under the hood, in a potted, die cast aluminum housing with a
sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and output speeds over 140 times a second and
responding to each new reading.
- This provides the precise friction element control needed to make smooth clutch-to-clutch shifts
for all gear changes.
As with most automatic transaxles, all shifts involve releasing one element and applying a different
element.
- In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to
ensure that it does not have excess capacity; the apply element is filled until it begins to make the
speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate
of speed change until the shift is complete.
The key to providing excellent shift quality is precision;
EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the
amount of that slip is typically less than a total of 20 degrees.
LEARNING
To achieve that precision, the EATX control module learns the characteristics of the particular
transaxle that it is controlling.
- It learns the release rate of the releasing element and the apply time of the applying element.
- It also learns the rate at which the apply element builds pressure sufficient to begin making the
speed change.
- This method achieves more precision than would be possible with exacting tolerances. It can also
adapt to any changes that occur with age or environment, for example, altitude, temperature,
engine output, etc.
KICKDOWN SHIFTING
For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate
at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing
element reapplies to maintain that speed until the apply element is filled.
This provides quick response since the engine begins to accelerate immediately and a smooth
torque exchange since the release element can control the rate of torque increase.
This control can make any power train feel more responsive without increasing harshness.
SUMMARY
Adaptive controls respond to input speed changes They compensate for changes in engine or
friction element torque and provide good, consistent shift quality for the life of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5447
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 (V6-201 3.3L (1994))
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 Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Relay > Page 5452
Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay
Transmission Relay Location
The Transmission Relay is located in LH side of engine compartment in the Power Distribution
Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Relay > Page 5453
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5454
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5459
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] >
Component Information > Locations
Overdrive Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] >
Component Information > Locations > Page 5465
Overdrive Off Switch (8 - Way)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5477
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 (V6-201 3.3L (1994))
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 5478
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 (V6-201 3.3L (1994))
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 5479
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5485
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 (V6-201 3.3L (1994))
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 5486
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5491
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 (V6-201 3.3L (1994))
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 5492
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 (V6-201 3.3L (1994))
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 5493
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5499
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 (V6-201 3.3L (1994))
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 5500
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5503
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 5504
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5507
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5510
Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range
The white Transmission Range Switch (formerly called PRNDL) is used as an input to the
Transmission Control Module, on the 4 speed electronic automatic transaxle.
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5513
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 (V6-201 3.3L (1994))
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 5514
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5523
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5528
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 (V6-201 3.3L (1994))
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 5529
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 (V6-201 3.3L (1994))
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 5530
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5536
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 5541
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 (V6-201 3.3L (1994))
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 5542
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 (V6-201 3.3L (1994))
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 5543
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 (V6-201 3.3L (1994))
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 5544
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Input (Turbine) Speed Sensor Connector > Page 5547
Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Page 5548
Transmission Speed Sensor: Description and Operation
Three pressure switches incorporated in an assembly with the solenoids identify solenoid
application.
Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds.
Position switch indicates manual shift lever position.
Engine speed, throttle position, temperature, etc., are also observed.
- Some of these signals are read directly from the engine control sensors; others are read from a
multiplex circuit with the powertrain control module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Page 5549
Transmission Speed Sensor: Testing and Inspection
INPUT (TURBINE) SPEED SENSOR INSPECTION
1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals 1 and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the input speed sensor.
OUTPUT SPEED SENSOR INSPECTION
1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input
speed sensor side connector terminals I and 2.
Standard value: 0.3k - 1.2k ohms
3. If the resistance is outside the standard value, replace the output speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 >
Diagrams > Page 5550
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS Warning Light ON Continuously
ABS Light: Customer Interest ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS Warning Light ON Continuously > Page 5564
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94
> ABS - Warning Light ON Continuously
ABS Light: All Technical Service Bulletins ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94
> ABS - Warning Light ON Continuously > Page 5570
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Technical Service Bulletins > Page 5571
ABS Light: Description and Operation
The ABS warning lamp will normally illuminate for one to two seconds when the ignition switch is
first turned to the On position.
Any time 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 to the On position), it will
activate the ABS warning lamp. When the lamp is on, only the anti-lock function of the brake
system is affected. The base brake system and ability to stop the vehicle will not be affected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay >
Component Information > Locations
ABS Main Relay: Locations
Fig. 19 Engine Compartment Wiring
Mounted on left fender side shield.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay >
Component Information > Locations > Page 5575
ABS Main Relay: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect wiring harness electrical connectors from relays,
then remove screw securing relay assembly to left front inner fender. 3. Reverse procedure to
install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Pump <-->
[Brake Fluid Pump] > Component Information > Description and Operation
ABS Pump: Description and Operation
The pump/motor assembly is located under the hydraulic assembly at the rear lefthand side of the
engine compartment. This electrically operated pump 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Pump <-->
[Brake Fluid Pump] > Component Information > Description and Operation > Page 5579
ABS Pump: Service and Repair
The pump/motor cannot be serviced independently from the modulator (hydraulic control unit). If it
is not function properly, the entire unit must be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump
Relay > Component Information > Locations
Brake Fluid Pump Relay: Locations
Fig. 19 Engine Compartment Wiring
Mounted on left fender side shield.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Diagrams
ABS Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Diagrams > Page 5589
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 information from the wheel speed sensors to control the anti-lock
brake system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Diagrams > Page 5590
Electronic Brake Control Module: Service and Repair
1. With ignition switch in Off position, disconnect both battery cables and remove battery, then
remove battery tray from vehicle. 2. Remove Controller Anti-lock Brake (CAB) from battery tray
support bracket. 3. Loosen bolt securing 60-way connector to CAB, then disconnect connector from
CAB by pulling straight out. Do not twist connector. 4. Remove CAB with its mounting bracket from
vehicle. 5. Reverse procedure to install, noting the following:
a. Ensure ignition switch is still in Off position before connecting 60-way connector to CAB. b.
Torque connector bolt to 38 inch lbs. and CAB assembly mounting bolt to 14 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Description and Operation
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
This system uses an integral hydraulic assembly which contains the wheel circuit valves used for
brake pressure modulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU)
Replacement
1. Remove fresh air intake and air cleaner assembly from engine. 2. Remove windshield washer
fluid reservoir, then disconnect electrical connectors from hydraulic assembly. 3. Drain as much
fluid from hydraulic reservoir as possible. 4. Disconnect pump high pressure line from hydraulic
unit. 5. Disconnect pump return hose from steel tube, then cap the end of the steel tube. 6.
Disconnect all brakes tubes from hydraulic assembly. 7. Remove retainer clip from brake pedal pin.
8. Remove four hydraulic mounting unit nuts, then the hydraulic unit. 9. Reverse procedure to
install, noting the following:
a. Torque mounting bolts to 21 ft. lbs. b. Lubricate bearing surface of pedal pin with lubricant. 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 12 ft. lbs.
g. Bleed brake system as described in this chapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement >
Page 5596
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Modulator Assembly
Replacement
1. Raise and support vehicle, then disconnect battery cables at battery. 2. Remove battery
hold-down and battery from battery tray, then remove battery tray and Controller Anti-Lock Brake
(CAB) from tray support
bracket.
3. Loosen battery tray support bracket to modulator assembly mounting bracket bolt, then the
battery tray support bracket to frame rail bolt. 4. Lift battery tray support bracket out of vehicle, then
remove battery acid shield from ABS modulator assembly. 5. Disconnect six brake tube fittings at
modulator assembly, thread savers and proportioning valves, then remove brake tube bundle from
modulator
assembly. It is not necessary to loosen fittings at junction block.
6. Raise and support vehicle, then disconnect wiring harness 10-way connector at modulator
assembly. 7. Remove bolt securing speed control servo to modulator bracket, then position servo
aside. 8. Loosen two bolts securing front of modulator bracket to frame rail, then loosen two rear
modulator bracket bolts. 9. Lower vehicle, then remove modulator assembly and bracket from
vehicle.
10. If necessary, separate modulator assembly from mounting bracket. 11. Reverse procedure to
install. Bleed base and anti-lock brake systems separately.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning
Light ON Continuously
Wheel Speed Sensor: Customer Interest ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning
Light ON Continuously > Page 5605
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions
Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number
81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5611
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5612
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5613
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5614
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5615
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5616
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5617
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5618
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5619
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5620
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5621
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5622
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5623
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5624
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5625
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5626
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5627
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5628
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5629
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5630
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5631
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5632
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5633
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5634
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5635
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
052294 > Dec > 94 > ABS - Warning Light ON Continuously
Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 5640
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis
Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed
Sensor Diagnosis
NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994
SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis
MODELS: 1993 - 1994
(AA) Spirit/Acclaim/LeBaron Sedan
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1994 (AP) Shadow/Shadow Convertible/Sundance
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS.
DISCUSSION:
Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection
have been and are continuing to be tested. An unusually large number of these wheel speed
sensors are being found to have no defects.
The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles:
The diagnostic manual MUST be followed without exception. No shortcuts should be used during
the diagnostic procedure.
All diagnostic work Must begin with test "1A".
All diagnostic work MUST end with "VER-1A".
Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as
preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications
Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications
NO.: 05-17-93 Rev. A
GROUP: Brakes
DATE: Dec. 22, 1993
SUBJECT: Left Front Wheel Speed Sensor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991-1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE
SYSTEM (ABS).
DISCUSSION:
On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel,
depending upon the model year. The difference between the two parts is the length of the wiring,
and they should not be interchanged.
P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this
part is used on prior model year vehicles the wiring may become damaged.
P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a **
later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to
the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring.
This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts
catalog bulletin is being developed and the parts catalog will be revised at a later date.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions
Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number
81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5654
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5655
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5656
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5657
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5658
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5659
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5660
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5661
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5662
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5663
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5664
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5665
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5666
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5667
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5668
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5669
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5670
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5671
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5672
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5673
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5674
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5675
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5676
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5677
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5678
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis
Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed
Sensor Diagnosis
NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994
SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis
MODELS: 1993 - 1994
(AA) Spirit/Acclaim/LeBaron Sedan
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1994 (AP) Shadow/Shadow Convertible/Sundance
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS.
DISCUSSION:
Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection
have been and are continuing to be tested. An unusually large number of these wheel speed
sensors are being found to have no defects.
The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles:
The diagnostic manual MUST be followed without exception. No shortcuts should be used during
the diagnostic procedure.
All diagnostic work Must begin with test "1A".
All diagnostic work MUST end with "VER-1A".
Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as
preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications
Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications
NO.: 05-17-93 Rev. A
GROUP: Brakes
DATE: Dec. 22, 1993
SUBJECT: Left Front Wheel Speed Sensor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991-1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE
SYSTEM (ABS).
DISCUSSION:
On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel,
depending upon the model year. The difference between the two parts is the length of the wiring,
and they should not be interchanged.
P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this
part is used on prior model year vehicles the wiring may become damaged.
P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a **
later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to
the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring.
This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts
catalog bulletin is being developed and the parts catalog will be revised at a later date.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 5687
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 (V6-201 3.3L (1994))
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
1. Raise and support vehicle, then remove wheel and tire assembly.
Fig. 252 Front Wheel Speed Sensor 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.
NOTE: 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 5 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 5690
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, noting the following: a. Torque sensor mounting bolt to 5 ft. lbs. b.
Torque U-bolt nuts to 65 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision
Brake Bleeding: Technical Service Bulletins Brakes - Bendix ABS System Bleeding Procedure
Revision
NUMBER: 05-01-94
GROUP: Brakes
DATE: May 27, 1994
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1994 Town & Country, Caravan and Voyager Service Manual - Publication No.
81-370-4105
DESCRIPTION OF CHANGES
Bendix Antilock 4 Bleed Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5695
5-76
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5696
5-77
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5697
5-78
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 5700
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
Brake System Bleeding
The content of this article reflects the changes called out by TSB 05-01-94.
The base brake system must be bled anytime air is permitted to enter the hydraulic system.
However, anti-lock brake system components should only be bled if the hydraulic control unit has
been removed or if there is reason to believe that air has entered the unit. The ABS portion of the
braking system must be bled separately. Under most circumstances, only the base brake system
will require bleeding. If the anti-lock brake system must be bled, proceed as follows:
1. Bleed base brake system, then remove battery, battery tray, support bracket and acid shield.
2. Using suitable jumper cables, reconnect battery to vehicle battery cables, then connect DRB
scan tool to diagnostic connector. Use extreme
caution to avoid arcs and shorts against vehicle body when battery is connected through cables.
3. Using DRB, ensure Controller Antilock Brake (CAB) has no stored diagnostic trouble codes. 4.
Bleed modulator primary check valve circuit, then the secondary check valve circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 5701
Fig. 242 Primary Check Valve Circuit Bleed Screw Location
Fig. 243 Secondary Check Valve Circuit Bleed Screw Location
a. Connect clear bleed tube to check valve circuit bleed screw, then place other end of tube in a
clear glass container partially filled with clean
brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening check valve circuit bleed screw one full
turn.
c. When brake pedal bottoms, tighten bleed screw, then release pedal. Do not release pedal until
bleed screw is tight. d. Repeat procedure until brake fluid flowing through tube appears bubble-free
and clean, then torque modulator assembly secondary bleed screw
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 5702
to 80 in. lbs. Do not remove bleed hose before screw is tight.
5. Bleed modulator primary sump circuit as follows:
Fig. 244 Primary Sump Circuit Bleed Screw Location
a. Connect clear bleed tube to primary sump circuit bleed screw, then place other end of tube in a
clear glass container partially filled with clean
brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening primary sump circuit bleed screw one
full turn.
c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit." Right front
and left rear solenoids will fire alternately for
approximately five seconds.
d. Continue to select "Primary Circuit" on DRB until brake fluid flowing through bleed tube is
bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears
bubble-free, repeat procedure. f.
Torque primary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube
from screw. Do not release pedal until bleed screw is tight.
6. Bleed modulator assembly primary accumulator circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 5703
Fig. 245 Primary Accumulator Circuit Bleed Screw Location
a. Connect clear bleed tube to primary accumulator circuit bleed screw, then place other end of
tube in a clear glass container partially filled with
clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using
DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit Valves." Right front and
left rear solenoids will fire
alternately for approximately five seconds.
d. Loosen primary accumulator circuit bleed screw one full turn. e. Continue bleeding primary
accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal
bottoms. f.
If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure.
g. Tighten primary accumulator bleed screw, then release brake pedal. Do not release pedal until
bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant
heavy force while opening primary accumulator circuit bleed screw one
full turn.
i. Without using DRB or allowing modulator solenoids to fire, bleed primary accumulator circuit until
brake fluid flowing through tube appears bubble-free and clean.
j. When brake fluid appears as specified, torque primary accumulator bleed screw to 80 in. lbs. and
release brake pedal. Do not release brake pedal until bleed screw is tight.
7. Bleed modulator assembly secondary sump circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 5704
Fig. 246 Secondary Sump Circuit Bleed Screw Location
a. Connect clear bleed tube to secondary sump circuit bleed screw, then place other end of tube in
a clear glass container partially filled with
clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening secondary sump circuit bleed screw one
full turn.
c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves."
Left front and right rear solenoids will fire
alternately for approximately five seconds.
d. Continue to select "Secondary Circuit Valves" on DRB until brake fluid flowing through bleed
tube is bubble-free or until brake pedal
bottoms.
e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f.
Torque secondary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed
tube from screw. Do not release pedal until bleed screw is tight.
8. Bleed modulator assembly secondary accumulator circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 5705
Fig. 247 Secondary Accumulator Circuit Bleed Screw Location
a. Connect clear bleed tube to secondary accumulator circuit bleed screw, then place other end of
tube in a clear glass container partially filled
with clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using
DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front
and right rear solenoids will fire
alternately for approximately five seconds.
d. Loosen secondary accumulator circuit bleed screw one full turn. e. Continue bleeding secondary
accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal
bottoms. f.
If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure.
g. Tighten secondary accumulator bleed screw, then release brake pedal. Do not release pedal
until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant
heavy force while opening secondary accumulator circuit bleed screw
one full turn.
i. Without using DRB or allowing modulator solenoids to fire, bleed secondary accumulator circuit
until brake fluid flowing through tube appears bubble-free and clean.
j. When brake fluid appears as specified, torque secondary accumulator bleed screw to 80 in. lbs.
and release brake pedal. Do not release brake pedal until bleed screw is tight.
9. Remove bleed tube and container, then install battery acid shield, tray support bracket, tray and
battery.
Pressure Bleeding
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 5706
Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure)
When bleeding ABS systems use only diaphragm type bleed pressure bleeder.
1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a
minimum of 40 times to de-pressurize hydraulic
accumulator.
2. On all models, 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, then 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information >
Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Bore and Piston Dimensions
Brake Caliper: Specifications
Caliper Bore I.D. 2.36 in
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Bore and Piston Dimensions > Page 5715
Brake Caliper: Specifications
Brake Hose To Caliper 24 ft.lb
Brake Hose To Intermediate Bracket 8 ft.lb
Brake Line Fittings 12 ft.lb
Caliper Pin Guide Bolts 30 ft.lb
Caliper Adapter Bolts 160 ft.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Page 5716
Disc Brake Caliper Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Page 5717
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 (V6-201 3.3L (1994))
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
Removal
For additional information see Removal Notes. See: Fundamentals and Basics
Disc Brake Caliper Assembly
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Reach to the inside of the caliper and pull it outboard as far as you can. This will push the piston
back into the bore of the caliper, making removal
of caliper easier.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5720
Fig 1 Removing And Installing Caliper Guide Pins
4. Remove caliper guide pin bolts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5721
Fig 2 Loosening Caliper Assembly From Adapter And Rotor
5. After removing caliper guide pin bolts, lift the caliper away from the braking disc with a pry bar or
screwdriver.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5722
Fig 3 Removing Or Installing Caliper Assembly
6. Remove caliper from disc and adapter by sliding caliper assembly out and away from braking
disc and adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5723
Fig 4 Storing Caliper
7. Support caliper firmly to prevent weight of caliper from damaging the flexible hose.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5724
Fig 5 Removing And Installing Outboard Shoe Assembly
8. Remove the outboard shoe assembly from the caliper adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5725
Fig 6 Removing And Installing Braking Disc
9. Remove the braking disc (rotor) from the hub by pulling it straight off the wheel mounting studs.
Fig 7 Removing And Installing Inboard Shoe Assembly
10. Remove the inboard shoe assembly by sliding it out along the bottom adapter abutment until
brake shoe assembly loosens from anti-rattle clip.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5726
Fig 8 Remove Or Install Anti-rattle Clip
11. Remove the anti-rattle clip from the top adapter abutment.
Installation
For additional information see Installation Notes. See: Fundamentals and Basics
Disc Brake Caliper Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5727
1. Thoroughly clean both adapter abutment rails. If there is any build-up of rust on the adapter
abutment rails, remove it using a wire brush DO NOT
SAND RAILS.
2. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant, or
equivalent.
Fig 8 Remove Or Install Anti-rattle Clip
3. Install the anti-rattle clip on the upper abutment of the caliper mounting adapter. 4. Remove the
protective paper from the noise suppression gasket on both the inner and outer brake shoe
assemblies (if equipped).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5728
Fig 7 Removing And Installing Inboard Shoe Assembly
Fig 6 Removing And Installing Braking Disc
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5729
5. Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter
abutment. Be careful not to get any grease from the
adapter way on the surface of the brake lining material. Be sure shoe assembly is correctly
positioned against anti-rattle clip.
6. Install braking disc by sliding it over wheel studs until it is seated against the face of the hub.
Fig 5 Removing And Installing Outboard Shoe Assembly
7. Slide the new outboard shoe assembly onto the adapter abutment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5730
Fig 3 Removing Or Installing Caliper Assembly
8. Carefully lower caliper over disc brake rotor and shoe assemblies. Make sure that the the caliper
guide pin bolts, bushings and sleeves are clear of
the adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5731
Fig 1 Removing And Installing Caliper Guide Pins
CAUTION: Use care to avoid cross threading guide pins when installing.
7. Install guide pins through bushing caliper and adapter and tighten to 25-35 ft lb (34-37 Nm). 8.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5732
Brake Caliper: Service and Repair Disassembly and Assembly
Disassembly
1. Remove caliper from adapter and rotor. Do not disconnect brake hose from caliper. Support
caliper at all times to prevent brake hose
damage.
2. Position caliper away from rotor to prevent brake fluid spillage on machined surface, then place
a small block of wood between caliper fingers to
prevent piston damage during removal.
3. Gently depress brake pedal to force caliper piston out of bore, then secure brake pedal at any
position below one inch of pedal travel to prevent
master cylinder brake fluid loss.
4. Disconnect brake hose at caliper, then mount caliper assembly in a soft jawed vise. Do not apply
excessive vise pressure; caliper damage will
result.
5. Use a suitable screwdriver to remove dust boot, then use a plastic trim stick or other suitable
non-metallic tool to pry piston seal out of piston bore
groove. Using a metallic tool for this operation may score piston bore.
6. Discard dust boot and piston seal; then, if necessary, remove caliper bushing and sleeve
assembly as follows:
Removing Inner Sleeve From Bushing
a. Push inner sleeve out of bushing far enough to grasp sleeve end, then pull sleeve from bushing.
b. Gently collapse one side of bushing, then pull on opposite end to remove from caliper assembly.
Assembly
1. Clamp caliper in soft jawed vise. Do not apply excessive vise pressure; caliper damage will
result. 2. Immerse new piston seal in clean brake fluid, then install in piston bore groove. 3. Coat
new piston boot with clean brake fluid, then position boot over piston and install piston in caliper
bore. Apply uniform force when pressing
piston into bore.
4. Position dust boot in caliper piston counterbore, then drive boot into counterbore using piston
caliper boot installer tool No. C-4689 and handle
tool No. C-4171, or equivalents.
5. Install guide pin sleeve bushings as follows:
a. Fold bushing in half lengthwise at solid middle section, then carefully insert bushing into caliper
assembly. b. Using fingers or a suitable soft dowel, unfold bushing to seat in caliper assembly.
Ensure flanges are seated evenly on both sides of bushing
hole.
6. Gently press guide pin sleeves through bushings until bushings seat in seal grooves, then
ensure bushings and sleeves are installed properly by
sliding each back and forth. Sleeves should slide easily and bushings should remain seated in
grooves.
7. Install caliper as outlined under Brake Pad/Service and Repair.
Cleaning, Inspecting & Honing Caliper
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5733
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.
Inspection
1. Clean all caliper components in alcohol or other suitable solvent and wipe dry. Ensure bores and
drilled passages are cleaned thoroughly. 2. Inspect piston bore for scoring or pitting. Crocus cloth
may be used to remove minor scratches or corrosion. 3. If piston bore exhibits deep scratches or
severe scoring, use caliper honing tool No. C-4095, or equivalent, to hone caliper bore. Do not
increase
bore diameter more than 0.001 inch.
4. If caliper piston bore is to be honed, honing tool stones and piston bore should be coated with
clean brake fluid, and honing should be followed by
cleaning with a stiff, non-metallic rotary brush.
5. If scoring and scratches cannot be removed without increasing piston bore beyond the specified
limit, caliper must be replaced. 6. Replace caliper piston if scored or pitted.
Kelsey-Hayes Double Pin Caliper
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5734
Disc Brake Caliper Assembly
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: a. Disconnect flexible brake line at frame bracket
after removing piston. b. Plug brake tube and remove piston from opposite caliper.
WARNING: Under no condition should air pressure be used to remove piston from bore! Personal
Injury could result from such practice.
5. Disconnect brake flexible hose from the caliper. 6. 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5735
Fig. 10 Dust Boot Removal
7. Support caliper and remove dust boot and discard.
Removing Piston Seal From Caliper
8. 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.
Bushing and Sleeve Assembly Service
NOTE: The bushing and sleeve assembly is a sealed for life unit. To service this unit:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5736
Removing Inner Sleeve From Bushing
a. Push out and then pull the inner sleeve from the inside of the bushing using your fingers as
shown.
Removing Bushing From Caliper
b. Using your fingers collapse one side of the bushing while pulling on the opposite side to remove
the bushing from the caliper assembly.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5737
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.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5738
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.
6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or
equivalent, drive boot into counterbore.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5739
Folded Caliper Guide Pin Bushing
Guide Pin Sleeve Bushing Installation a. Fold the bushing in half lengthwise at the solid middle
section of the bushing.
Removing Bushing From Caliper
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5740
Installing Caliper Guide Pin Bushing
b. Using your fingers insert the folded bushing into the caliper assembly. Making sure the solid
section of the bushing is fully seated into the
bushing hole of the caliper assembly. Do not use a sharp object to perform this step due to
possible damage to the bushing.
Bushing Correctly Installed In Caliper
c. Unfold the bushing using your fingers or wooden dowel until the bushing is fully seated into the
caliper assembly with the flanges seated
evenly on both sides of the bushing holes in the caliper assembly.
Fig 7 Installing Caliper Sleeves
Guide Pin Sleeve Installation a. Install the sleeve into one end of the bushing until the seal area of
the bushing is past the seal groove in the sleeve.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5741
b. Holding the convoluted end of the bushing with one hand. Push the sleeve through the bushing
until the one end of the bushing is fully seaated
into the seal groove on the one end of the sleeve.
Fig 8 Installed Caliper Bushing Sleeve
c. Holding the sleeve in place work the other end of the bushing over the end of the sleeve and into
the seal groove. Be sure the other end of the
bushing did not come out of the seal groove in the sleeve.
c. When the sleeve is seated properly into the bushing. The sealed for life bushing can be held
between your finger and easily slid back and forth
without the bushing seal unseating from the sleeve.
NOTE: Before installing caliper assembly on vehicle, inspect braking disc for runout, thickness, and
thickness variation.
7. Install caliper assembly.
CAUTION: Always use new seal washers when installing brake hose to caliper.
8. Install brake hose to caliper using new seal washers, tighten banjo bolt to 33 Nm (24 ft lb). 9.
Bleed the brake system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes > Page 5744
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes > Page 5745
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Page 5749
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 (V6-201 3.3L (1994))
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
Disc Brake Caliper Assembly
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Reach to the inside of the caliper and pull it outboard as far as you can. This will push the piston
back into the bore of the caliper, making removal
of caliper easier.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5752
Fig 1 Removing And Installing Caliper Guide Pins
4. Remove caliper guide pin bolts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5753
Fig 2 Loosening Caliper Assembly From Adapter And Rotor
5. After removing caliper guide pin bolts, lift the caliper away from the braking disc with a pry bar or
screwdriver.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5754
Fig 3 Removing Or Installing Caliper Assembly
6. Remove caliper from disc and adapter by sliding caliper assembly out and away from braking
disc and adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5755
Fig 4 Storing Caliper
7. Support caliper firmly to prevent weight of caliper from damaging the flexible hose.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5756
Fig 5 Removing And Installing Outboard Shoe Assembly
8. Remove the outboard shoe assembly from the caliper adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5757
Fig 6 Removing And Installing Braking Disc
9. Remove the braking disc (rotor) from the hub by pulling it straight off the wheel mounting studs.
Fig 7 Removing And Installing Inboard Shoe Assembly
10. Remove the inboard shoe assembly by sliding it out along the bottom adapter abutment until
brake shoe assembly loosens from anti-rattle clip.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5758
Fig 8 Remove Or Install Anti-rattle Clip
11. Remove the anti-rattle clip from the top adapter abutment.
Installation
For additional information see Installation Notes. See: Brake Caliper/Fundamentals and Basics
Disc Brake Caliper Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5759
1. Thoroughly clean both adapter abutment rails. If there is any build-up of rust on the adapter
abutment rails, remove it using a wire brush DO NOT
SAND RAILS.
2. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant, or
equivalent.
Fig 8 Remove Or Install Anti-rattle Clip
3. Install the anti-rattle clip on the upper abutment of the caliper mounting adapter. 4. Remove the
protective paper from the noise suppression gasket on both the inner and outer brake shoe
assemblies (if equipped).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5760
Fig 7 Removing And Installing Inboard Shoe Assembly
Fig 6 Removing And Installing Braking Disc
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5761
5. Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter
abutment. Be careful not to get any grease from the
adapter way on the surface of the brake lining material. Be sure shoe assembly is correctly
positioned against anti-rattle clip.
6. Install braking disc by sliding it over wheel studs until it is seated against the face of the hub.
Fig 5 Removing And Installing Outboard Shoe Assembly
7. Slide the new outboard shoe assembly onto the adapter abutment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5762
Fig 3 Removing Or Installing Caliper Assembly
8. Carefully lower caliper over disc brake rotor and shoe assemblies. Make sure that the the caliper
guide pin bolts, bushings and sleeves are clear of
the adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5763
Fig 1 Removing And Installing Caliper Guide Pins
CAUTION: Use care to avoid cross threading guide pins when installing.
7. Install guide pins through bushing caliper and adapter and tighten to 25-35 ft lb (34-37 Nm). 8.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 5764
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Specifications
Brake Disc: Specifications
Nominal Thickness 0.939 - 0.949 in
Minimum Thickness 0.881 in
Rotor Runout 0.005 in
Hub Runout 0.003 in
Thickness Variation 0.0005 in
Rotor Finish 15-80 micro-in
Fig 1 Checking Total Indicated Runout (TIR)
Fig 3 Checking Hub Runout
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Specifications > Page 5768
Fig 5 Checking Disc Thickness
Fig 7 Refacing Brake Disc -- Final Finish
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service Precautions > Brake Disc Service
Brake Disc: Service Precautions Brake Disc Service
Servicing of disc brakes is extremely critical due to the close tolerances required in machining the
brake disc to ensure proper brake operation.
The maintenance of these close controls on the friction surfaces is necessary to prevent brake
roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch
finish. This close control of the rubbing surface finish is necessary to avoid pulls and erratic
performance and promote long lining life and equal lining wear of both left and right brakes.
Refinishing of the rubbing surfaces should not be attempted unless precision equipment, capable
of measuring in micro-inches (millionths of an inch) is available.
To check runout of a disc, mount a dial indicator on a convenient part (steering knuckle, tie rod,
disc brake caliper housing) so that the plunger of the dial indicator contacts the disc at a point one
inch from the outer edge. If the total indicated runout exceeds specifications, install a new disc.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service Precautions > Brake Disc Service > Page 5771
Brake Disc: Service Precautions Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If
roughness or vibration is encountered during highway operation or if pedal pumping is experienced
at low speeds, the disc may have excessive thickness variation. To check for this condition,
measure the disc at 8 points with a micrometer at a radius approximately one inch from edge of
disc. If thickness measurements vary more than specifications allow, the disc should be replaced
with a new one.
Excessive lateral runout of braking disc may cause a "knocking back" of the pistons, possibly
creating increased pedal travel and vibration when brakes are applied.
Before checking the runout, wheel bearings should be adjusted. Be sure to make the adjustment
according to the recommendations given in that section.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service Precautions > Page 5772
Brake 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service Precautions > Page 5773
- 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service Precautions > Page 5774
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service and Repair > Rotor Removal and Installation
Brake 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service and Repair > Rotor Removal and Installation > Page 5777
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service and Repair > Rotor Removal and Installation > Page 5778
Brake 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Service and Repair > Rotor Removal and Installation > Page 5779
- 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.
Minimum Allowable Thickness
...................................................................................................................................................
22.4mm (0.881 in)
NOTE: For additional information on how to use a micrometer, see Fundamentals and Basics. See:
Fundamentals and Basics
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Fundamentals and Basics > How to Use A Micrometer
Brake 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 5782
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 5783
Brake 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] >
Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 5784
Brake 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 (V6-201 3.3L (1994))
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
..........................................................................................................................................................
109 Nm (80 ft lb)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications > Page 5789
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications > Page 5790
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications > Page 5791
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information
> Testing and Inspection
Brake Adjuster: Testing and Inspection
ADJUSTER MECHANISM
Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster
mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet
and replace as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal > Page 5800
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 129 Nm (95 ft lb)
3. Adjust rear brakes.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal > Page 5801
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service Precautions
Brake Shoe: Service Precautions
Prior to removing brake shoes it is recommended that a suitable clip or restraining device be
applied to the wheel cylinders to prevent wheel cylinder pistons from being pushed out of their
bores.
Do not intermix automatic adjuster components from side to side.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service Precautions > Page 5805
Brake Shoe: Testing 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service Precautions > Page 5806
Brake Shoe: Adjustments
The rear brakes are self-adjusting. An initial adjustment is necessary after the brake shoes have
been relined or replaced, or when the length of the star wheel adjuster has been changed during
other service operations. To adjust the rear brakes, proceed as follows:
1. Raise and support vehicle. 2. Remove adjusting hole covers from brake support plates. 3.
Release parking brake and back off adjustment to slacken cable. 4. Insert brake adjusting tool No.
C-3784, or equivalent, through adjusting hole and into contact with star wheel of adjusting screw. 5.
Move handle of tool upward to turn star wheel until a slight drag is felt while turning wheel. 6. Insert
a suitable tool into brake adjusting hole and push adjusting lever out of engagement with star
wheel. Use caution not to bend adjusting
lever or distort lever spring.
7. Using adjusting tool, back off star wheel until no brake shoe drag is felt while turning wheel. 8.
Adjust parking brake as outlined under Parking Brake/Adjustments, then install adjusting hole
covers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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.
NOTE: Support plates and park brake assemblies are NOT SYMMETRICALLY OPPOSITE.
Right Side: Parking brake cable enters the support plate at the rear and attaches to the lever
attached to the primary shoe. Right side support and cable assembly is color coded gray.
- Left Side: Parking brake cable enters the support plate at the front (traditional) and attaches to the
lever attached to the secondary shoe. Left side support and cable assembly is color coded black.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5809
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. 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5810
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.
NOTE: Support plates and park brake assemblies are NOT SYMMETRICALLY OPPOSITE.
- Right Side: Parking brake cable enters the support plate at the rear and attaches to the lever
attached to the primary shoe. Right side support and cable assembly is color coded gray.
- Left Side: Parking brake cable enters the support plate at the front (traditional) and attaches to the
lever attached to the secondary shoe. Left side support and cable assembly is color coded black.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5811
Fig 7 Removing Of Installing Parking Brake Strut And Spring
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 (left side) or primary shoe (right
side).
Installing Brake Shoes
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5812
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5813
Brake Shoe: Service and Repair Cleaning and Inspection
Brake Linings
1. Inspect components for damage and unusual wear. Replace as necessary. 2. Inspect wheel
cylinders. Boots which are torn, cut or heat damaged indicate need for wheel cylinder replacement.
Peel back lower edge of boot. If
fluid spills out, cup leakage is indicated and wheel cylinder should be replaced.
NOTE: A slight amount of fluid is always present and considered normal, acting as a lubricant for
the cylinder pistons.
3. Inspect backing plate for evidence of axle seal leakage. If leakage exists, refer to individual
vehicle chapter for axle seal replacement procedure. 4. Inspect backing plate attaching bolts, and
ensure they are tight. 5. Inspect adjuster screw operation. If satisfactory, lightly lubricate adjusting
screw and washer with suitable brake lube. If operation is
unsatisfactory, replace.
6. Using fine emery cloth or other suitable abrasive, clean rust and dirt from shoe contact surfaces
on backing plate.
Brake Linings & Springs
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications > Bore Diameter > Page 5818
Wheel Cylinder: Specifications
Wheel Cylinder To Support Plate 6 ft.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications > Page 5819
Fig 3 Wheel Cylinder
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5822
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5823
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5824
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5825
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision
Brake Bleeding: Technical Service Bulletins Brakes - Bendix ABS System Bleeding Procedure
Revision
NUMBER: 05-01-94
GROUP: Brakes
DATE: May 27, 1994
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1994 Town & Country, Caravan and Voyager Service Manual - Publication No.
81-370-4105
DESCRIPTION OF CHANGES
Bendix Antilock 4 Bleed Procedure
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5831
5-76
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Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5832
5-77
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Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5833
5-78
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 5836
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
Brake System Bleeding
The content of this article reflects the changes called out by TSB 05-01-94.
The base brake system must be bled anytime air is permitted to enter the hydraulic system.
However, anti-lock brake system components should only be bled if the hydraulic control unit has
been removed or if there is reason to believe that air has entered the unit. The ABS portion of the
braking system must be bled separately. Under most circumstances, only the base brake system
will require bleeding. If the anti-lock brake system must be bled, proceed as follows:
1. Bleed base brake system, then remove battery, battery tray, support bracket and acid shield.
2. Using suitable jumper cables, reconnect battery to vehicle battery cables, then connect DRB
scan tool to diagnostic connector. Use extreme
caution to avoid arcs and shorts against vehicle body when battery is connected through cables.
3. Using DRB, ensure Controller Antilock Brake (CAB) has no stored diagnostic trouble codes. 4.
Bleed modulator primary check valve circuit, then the secondary check valve circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 5837
Fig. 242 Primary Check Valve Circuit Bleed Screw Location
Fig. 243 Secondary Check Valve Circuit Bleed Screw Location
a. Connect clear bleed tube to check valve circuit bleed screw, then place other end of tube in a
clear glass container partially filled with clean
brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening check valve circuit bleed screw one full
turn.
c. When brake pedal bottoms, tighten bleed screw, then release pedal. Do not release pedal until
bleed screw is tight. d. Repeat procedure until brake fluid flowing through tube appears bubble-free
and clean, then torque modulator assembly secondary bleed screw
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 5838
to 80 in. lbs. Do not remove bleed hose before screw is tight.
5. Bleed modulator primary sump circuit as follows:
Fig. 244 Primary Sump Circuit Bleed Screw Location
a. Connect clear bleed tube to primary sump circuit bleed screw, then place other end of tube in a
clear glass container partially filled with clean
brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening primary sump circuit bleed screw one
full turn.
c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit." Right front
and left rear solenoids will fire alternately for
approximately five seconds.
d. Continue to select "Primary Circuit" on DRB until brake fluid flowing through bleed tube is
bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears
bubble-free, repeat procedure. f.
Torque primary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube
from screw. Do not release pedal until bleed screw is tight.
6. Bleed modulator assembly primary accumulator circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 5839
Fig. 245 Primary Accumulator Circuit Bleed Screw Location
a. Connect clear bleed tube to primary accumulator circuit bleed screw, then place other end of
tube in a clear glass container partially filled with
clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using
DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit Valves." Right front and
left rear solenoids will fire
alternately for approximately five seconds.
d. Loosen primary accumulator circuit bleed screw one full turn. e. Continue bleeding primary
accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal
bottoms. f.
If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure.
g. Tighten primary accumulator bleed screw, then release brake pedal. Do not release pedal until
bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant
heavy force while opening primary accumulator circuit bleed screw one
full turn.
i. Without using DRB or allowing modulator solenoids to fire, bleed primary accumulator circuit until
brake fluid flowing through tube appears bubble-free and clean.
j. When brake fluid appears as specified, torque primary accumulator bleed screw to 80 in. lbs. and
release brake pedal. Do not release brake pedal until bleed screw is tight.
7. Bleed modulator assembly secondary sump circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 5840
Fig. 246 Secondary Sump Circuit Bleed Screw Location
a. Connect clear bleed tube to secondary sump circuit bleed screw, then place other end of tube in
a clear glass container partially filled with
clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while
loosening secondary sump circuit bleed screw one
full turn.
c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves."
Left front and right rear solenoids will fire
alternately for approximately five seconds.
d. Continue to select "Secondary Circuit Valves" on DRB until brake fluid flowing through bleed
tube is bubble-free or until brake pedal
bottoms.
e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f.
Torque secondary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed
tube from screw. Do not release pedal until bleed screw is tight.
8. Bleed modulator assembly secondary accumulator circuit as follows:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 5841
Fig. 247 Secondary Accumulator Circuit Bleed Screw Location
a. Connect clear bleed tube to secondary accumulator circuit bleed screw, then place other end of
tube in a clear glass container partially filled
with clean brake fluid.
b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using
DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front
and right rear solenoids will fire
alternately for approximately five seconds.
d. Loosen secondary accumulator circuit bleed screw one full turn. e. Continue bleeding secondary
accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal
bottoms. f.
If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure.
g. Tighten secondary accumulator bleed screw, then release brake pedal. Do not release pedal
until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant
heavy force while opening secondary accumulator circuit bleed screw
one full turn.
i. Without using DRB or allowing modulator solenoids to fire, bleed secondary accumulator circuit
until brake fluid flowing through tube appears bubble-free and clean.
j. When brake fluid appears as specified, torque secondary accumulator bleed screw to 80 in. lbs.
and release brake pedal. Do not release brake pedal until bleed screw is tight.
9. Remove bleed tube and container, then install battery acid shield, tray support bracket, tray and
battery.
Pressure Bleeding
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 5842
Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure)
When bleeding ABS systems use only diaphragm type bleed pressure bleeder.
1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a
minimum of 40 times to de-pressurize hydraulic
accumulator.
2. On all models, 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, then 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Bore and Piston Dimensions
Brake Caliper: Specifications
Caliper Bore I.D. 2.36 in
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Bore and Piston Dimensions > Page 5847
Brake Caliper: Specifications
Brake Hose To Caliper 24 ft.lb
Brake Hose To Intermediate Bracket 8 ft.lb
Brake Line Fittings 12 ft.lb
Caliper Pin Guide Bolts 30 ft.lb
Caliper Adapter Bolts 160 ft.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Page 5848
Disc Brake Caliper Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Page 5849
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 (V6-201 3.3L (1994))
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
Removal
For additional information see Removal Notes. See: Fundamentals and Basics
Disc Brake Caliper Assembly
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Reach to the inside of the caliper and pull it outboard as far as you can. This will push the piston
back into the bore of the caliper, making removal
of caliper easier.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5852
Fig 1 Removing And Installing Caliper Guide Pins
4. Remove caliper guide pin bolts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5853
Fig 2 Loosening Caliper Assembly From Adapter And Rotor
5. After removing caliper guide pin bolts, lift the caliper away from the braking disc with a pry bar or
screwdriver.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5854
Fig 3 Removing Or Installing Caliper Assembly
6. Remove caliper from disc and adapter by sliding caliper assembly out and away from braking
disc and adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5855
Fig 4 Storing Caliper
7. Support caliper firmly to prevent weight of caliper from damaging the flexible hose.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5856
Fig 5 Removing And Installing Outboard Shoe Assembly
8. Remove the outboard shoe assembly from the caliper adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5857
Fig 6 Removing And Installing Braking Disc
9. Remove the braking disc (rotor) from the hub by pulling it straight off the wheel mounting studs.
Fig 7 Removing And Installing Inboard Shoe Assembly
10. Remove the inboard shoe assembly by sliding it out along the bottom adapter abutment until
brake shoe assembly loosens from anti-rattle clip.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5858
Fig 8 Remove Or Install Anti-rattle Clip
11. Remove the anti-rattle clip from the top adapter abutment.
Installation
For additional information see Installation Notes. See: Fundamentals and Basics
Disc Brake Caliper Assembly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5859
1. Thoroughly clean both adapter abutment rails. If there is any build-up of rust on the adapter
abutment rails, remove it using a wire brush DO NOT
SAND RAILS.
2. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant, or
equivalent.
Fig 8 Remove Or Install Anti-rattle Clip
3. Install the anti-rattle clip on the upper abutment of the caliper mounting adapter. 4. Remove the
protective paper from the noise suppression gasket on both the inner and outer brake shoe
assemblies (if equipped).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5860
Fig 7 Removing And Installing Inboard Shoe Assembly
Fig 6 Removing And Installing Braking Disc
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5861
5. Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter
abutment. Be careful not to get any grease from the
adapter way on the surface of the brake lining material. Be sure shoe assembly is correctly
positioned against anti-rattle clip.
6. Install braking disc by sliding it over wheel studs until it is seated against the face of the hub.
Fig 5 Removing And Installing Outboard Shoe Assembly
7. Slide the new outboard shoe assembly onto the adapter abutment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5862
Fig 3 Removing Or Installing Caliper Assembly
8. Carefully lower caliper over disc brake rotor and shoe assemblies. Make sure that the the caliper
guide pin bolts, bushings and sleeves are clear of
the adapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5863
Fig 1 Removing And Installing Caliper Guide Pins
CAUTION: Use care to avoid cross threading guide pins when installing.
7. Install guide pins through bushing caliper and adapter and tighten to 25-35 ft lb (34-37 Nm). 8.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5864
Brake Caliper: Service and Repair Disassembly and Assembly
Disassembly
1. Remove caliper from adapter and rotor. Do not disconnect brake hose from caliper. Support
caliper at all times to prevent brake hose
damage.
2. Position caliper away from rotor to prevent brake fluid spillage on machined surface, then place
a small block of wood between caliper fingers to
prevent piston damage during removal.
3. Gently depress brake pedal to force caliper piston out of bore, then secure brake pedal at any
position below one inch of pedal travel to prevent
master cylinder brake fluid loss.
4. Disconnect brake hose at caliper, then mount caliper assembly in a soft jawed vise. Do not apply
excessive vise pressure; caliper damage will
result.
5. Use a suitable screwdriver to remove dust boot, then use a plastic trim stick or other suitable
non-metallic tool to pry piston seal out of piston bore
groove. Using a metallic tool for this operation may score piston bore.
6. Discard dust boot and piston seal; then, if necessary, remove caliper bushing and sleeve
assembly as follows:
Removing Inner Sleeve From Bushing
a. Push inner sleeve out of bushing far enough to grasp sleeve end, then pull sleeve from bushing.
b. Gently collapse one side of bushing, then pull on opposite end to remove from caliper assembly.
Assembly
1. Clamp caliper in soft jawed vise. Do not apply excessive vise pressure; caliper damage will
result. 2. Immerse new piston seal in clean brake fluid, then install in piston bore groove. 3. Coat
new piston boot with clean brake fluid, then position boot over piston and install piston in caliper
bore. Apply uniform force when pressing
piston into bore.
4. Position dust boot in caliper piston counterbore, then drive boot into counterbore using piston
caliper boot installer tool No. C-4689 and handle
tool No. C-4171, or equivalents.
5. Install guide pin sleeve bushings as follows:
a. Fold bushing in half lengthwise at solid middle section, then carefully insert bushing into caliper
assembly. b. Using fingers or a suitable soft dowel, unfold bushing to seat in caliper assembly.
Ensure flanges are seated evenly on both sides of bushing
hole.
6. Gently press guide pin sleeves through bushings until bushings seat in seal grooves, then
ensure bushings and sleeves are installed properly by
sliding each back and forth. Sleeves should slide easily and bushings should remain seated in
grooves.
7. Install caliper as outlined under Brake Pad/Service and Repair.
Cleaning, Inspecting & Honing Caliper
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5865
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.
Inspection
1. Clean all caliper components in alcohol or other suitable solvent and wipe dry. Ensure bores and
drilled passages are cleaned thoroughly. 2. Inspect piston bore for scoring or pitting. Crocus cloth
may be used to remove minor scratches or corrosion. 3. If piston bore exhibits deep scratches or
severe scoring, use caliper honing tool No. C-4095, or equivalent, to hone caliper bore. Do not
increase
bore diameter more than 0.001 inch.
4. If caliper piston bore is to be honed, honing tool stones and piston bore should be coated with
clean brake fluid, and honing should be followed by
cleaning with a stiff, non-metallic rotary brush.
5. If scoring and scratches cannot be removed without increasing piston bore beyond the specified
limit, caliper must be replaced. 6. Replace caliper piston if scored or pitted.
Kelsey-Hayes Double Pin Caliper
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5866
Disc Brake Caliper Assembly
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: a. Disconnect flexible brake line at frame bracket
after removing piston. b. Plug brake tube and remove piston from opposite caliper.
WARNING: Under no condition should air pressure be used to remove piston from bore! Personal
Injury could result from such practice.
5. Disconnect brake flexible hose from the caliper. 6. 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5867
Fig. 10 Dust Boot Removal
7. Support caliper and remove dust boot and discard.
Removing Piston Seal From Caliper
8. 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.
Bushing and Sleeve Assembly Service
NOTE: The bushing and sleeve assembly is a sealed for life unit. To service this unit:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5868
Removing Inner Sleeve From Bushing
a. Push out and then pull the inner sleeve from the inside of the bushing using your fingers as
shown.
Removing Bushing From Caliper
b. Using your fingers collapse one side of the bushing while pulling on the opposite side to remove
the bushing from the caliper assembly.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5869
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.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5870
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.
6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or
equivalent, drive boot into counterbore.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5871
Folded Caliper Guide Pin Bushing
Guide Pin Sleeve Bushing Installation a. Fold the bushing in half lengthwise at the solid middle
section of the bushing.
Removing Bushing From Caliper
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5872
Installing Caliper Guide Pin Bushing
b. Using your fingers insert the folded bushing into the caliper assembly. Making sure the solid
section of the bushing is fully seated into the
bushing hole of the caliper assembly. Do not use a sharp object to perform this step due to
possible damage to the bushing.
Bushing Correctly Installed In Caliper
c. Unfold the bushing using your fingers or wooden dowel until the bushing is fully seated into the
caliper assembly with the flanges seated
evenly on both sides of the bushing holes in the caliper assembly.
Fig 7 Installing Caliper Sleeves
Guide Pin Sleeve Installation a. Install the sleeve into one end of the bushing until the seal area of
the bushing is past the seal groove in the sleeve.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5873
b. Holding the convoluted end of the bushing with one hand. Push the sleeve through the bushing
until the one end of the bushing is fully seaated
into the seal groove on the one end of the sleeve.
Fig 8 Installed Caliper Bushing Sleeve
c. Holding the sleeve in place work the other end of the bushing over the end of the sleeve and into
the seal groove. Be sure the other end of the
bushing did not come out of the seal groove in the sleeve.
c. When the sleeve is seated properly into the bushing. The sealed for life bushing can be held
between your finger and easily slid back and forth
without the bushing seal unseating from the sleeve.
NOTE: Before installing caliper assembly on vehicle, inspect braking disc for runout, thickness, and
thickness variation.
7. Install caliper assembly.
CAUTION: Always use new seal washers when installing brake hose to caliper.
8. Install brake hose to caliper using new seal washers, tighten banjo bolt to 33 Nm (24 ft lb). 9.
Bleed the brake system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes > Page 5876
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes > Page 5877
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 5881
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 5882
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure
Sensor/Switch > Component Information > Description and Operation
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 (V6-201 3.3L (1994))
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)
................................................................................................................................ 17 Nm (143 in lb)
Brake hoses to calipers (banjo bolts)
............................................................................................................................................................
33 Nm (24 ft lb) Brake hose intermediate bracket ...............................................................................
.................................................................................... 11 Nm (95 in lb)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 5889
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Hold-Off Valve
Brake Proportioning/Combination Valve: Description and Operation Hold-Off Valve
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. This allows 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Hold-Off Valve > Page 5894
Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve
There are two basic types of proportioning valves, one of which is height sensitive. Vehicles may
have either one or both of these valves.
On the first type, the proportioning valve operates by transmitting full input pressure to the rear
brakes up to a certain point, called the split point, then reducing the amount of pressure increase to
the rear brakes beyond the split point according to a certain ratio. On light pedal applications,
approximately equal brake pressure is transmitted to both front and rear brakes, while at higher
pressures, pressure transmitted to rear brakes is lower than that transmitted to front brakes to
prevent premature rear wheel lock-up. If hydraulic pressure is lost in front brake system, rear brake
system hydraulic pressure moves the brake warning switch piston, opening a bypass in the
proportioning valve to allow full rear brake hydraulic pressure.
Fig. 1 Typical height sensing proportioning valve
The height sensing type of proportioning valve is located under the load bed just forward of the rear
axle. This valve automatically provides optimum front-to-rear brake balance regardless of vehicle
load. Pressure to the rear brakes is modulated by the proportioning valve sensing vehicle load
through relative movement between rear axle and load floor. The valve is mounted to a load floor
crossmember. A large external spring is connected between a lever mounted on the valve and an
adjustable bracket mounted on the rear axle. Higher brake line pressure is allowed as the load
increases. The proportioning valve transmits full input pressure to rear brakes up to a certain point
called the split point, and beyond that point reduces the amount of pressure increase to the rear
brakes according to a certain ratio, preventing premature wheel lock-up.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Page 5895
Brake Proportioning/Combination Valve: Testing and Inspection
These models use a proportioning valve and pressure differential switch, or a combination valve.
When a premature rear wheel skid is obtained during braking, it may be an indication that fluid
pressure to rear brakes is above a desired output and/or a malfunction has occurred within the
valve. At this time, the valve unit should be tested as follows:
Fig. 2 Height Sensing Proportioning Valve Assembly
1. Remove actuator assembly adjustment nut, then disconnect assembly from valve lever and
remove.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Page 5896
Fig. 3 Master Cylinder & Brake Warning Switch
2. Install gauge and Tee from line pressure set No. C-4007, or equivalent, inline with either master
cylinder port to the brake valve assembly. 3. Install second gauge from line pressure set No.
C-4007, or equivalent, to either rear brake outlet port between valve assembly and rear brake line.
Bleed both hydraulic circuits and the gauges.
4. Have an assistant exert pressure on the brake pedal to get a reading on the outlet gauge. Outlet
test pressure should read 100-200 psi. 5. Inlet pressure should be 500 psi. If not, replace valve and
torque mounting bolts to 250 inch lbs. 6. If both gauges read correctly, reinstall actuator assembly,
then adjust and road test vehicle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Page 5897
Brake Proportioning/Combination Valve: Service and Repair
The proportioning valves should never be disassembled.
1. Raise and support vehicle, then access modulator assembly by removing the battery, tray, tray
support bracket and acid shield as described under
Modulator Assembly/Service and Repair.
2. Disconnect brake tube fitting at proportioning valve, then remove valve from modulator
assembly. 3. Reverse procedure to install, noting the following:
a. Coat proportioning valve O-ring with clean brake fluid prior to installation. b. Bleed base and
anti-lock brake systems separately.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
This system uses an integral hydraulic assembly which contains the wheel circuit valves used for
brake pressure modulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU)
Replacement
1. Remove fresh air intake and air cleaner assembly from engine. 2. Remove windshield washer
fluid reservoir, then disconnect electrical connectors from hydraulic assembly. 3. Drain as much
fluid from hydraulic reservoir as possible. 4. Disconnect pump high pressure line from hydraulic
unit. 5. Disconnect pump return hose from steel tube, then cap the end of the steel tube. 6.
Disconnect all brakes tubes from hydraulic assembly. 7. Remove retainer clip from brake pedal pin.
8. Remove four hydraulic mounting unit nuts, then the hydraulic unit. 9. Reverse procedure to
install, noting the following:
a. Torque mounting bolts to 21 ft. lbs. b. Lubricate bearing surface of pedal pin with lubricant. 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 12 ft. lbs.
g. Bleed brake system as described in this chapter.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5903
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Modulator Assembly
Replacement
1. Raise and support vehicle, then disconnect battery cables at battery. 2. Remove battery
hold-down and battery from battery tray, then remove battery tray and Controller Anti-Lock Brake
(CAB) from tray support
bracket.
3. Loosen battery tray support bracket to modulator assembly mounting bracket bolt, then the
battery tray support bracket to frame rail bolt. 4. Lift battery tray support bracket out of vehicle, then
remove battery acid shield from ABS modulator assembly. 5. Disconnect six brake tube fittings at
modulator assembly, thread savers and proportioning valves, then remove brake tube bundle from
modulator
assembly. It is not necessary to loosen fittings at junction block.
6. Raise and support vehicle, then disconnect wiring harness 10-way connector at modulator
assembly. 7. Remove bolt securing speed control servo to modulator bracket, then position servo
aside. 8. Loosen two bolts securing front of modulator bracket to frame rail, then loosen two rear
modulator bracket bolts. 9. Lower vehicle, then remove modulator assembly and bracket from
vehicle.
10. If necessary, separate modulator assembly from mounting bracket. 11. Reverse procedure to
install. Bleed base and anti-lock brake systems separately.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Diagrams > Page 5907
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Diagrams > Page 5908
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Diagrams > Page 5909
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 (V6-201 3.3L (1994))
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)
................................................................................................................................ 17 Nm (143 in lb)
Master cylinder to brake booster mounting nuts
......................................................................................................................................... 28 Nm (250
in lb) Brake booster assembly to dash panel
........................................................................................................................................................ 28
Nm (250 in lb)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > Page 5913
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > Page 5914
Brake Master Cylinder: Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > Page 5915
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > Page 5916
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > Page 5917
Brake Master Cylinder: Adjustments
Not adjustable
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Manual Bleeding
1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a
minimum of 40 times to de-pressurize hydraulic
accumulator.
2. On all models, connect a suitable transparent hose to bleeder valve on right rear wheel cylinder
and submerge other end in a glass container
partially filled with clean brake fluid.
3. Pump brake pedal several times, then hold pedal down firmly. 4. With pedal firmly depressed,
open bleeder valve of right rear brake until pedal fades to floor, then close bleeder valve. 5. Repeat
procedure until a continuous flow of brake fluid is released from bleeder valve. Ensure a fluid level
is maintained in master cylinder at
all times.
6. Perform Steps 2 through 5 for left rear, right front, and left front brakes in that order. 7. After
bleeding of brakes is completed, road test vehicle to ensure brakes are operating correctly and
pedal is solid.
Pressure Bleeding
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5920
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.
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5921
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5922
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5923
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5924
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Page 5925
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5928
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5929
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5930
- 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5931
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Bore Diameter > Page 5936
Wheel Cylinder: Specifications
Wheel Cylinder To Support Plate 6 ft.lb
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Page 5937
Fig 3 Wheel Cylinder
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5940
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5941
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5942
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 5943
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Diagrams > Page 5948
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 (V6-201 3.3L (1994))
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
FRONT PARKING BRAKE CABLE
Remove
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5951
Parking Brake Cable Routing FWD & AWD
Removing Brake Cable From Brake Support Plate
1. Loosen cable adjusting nut and disengage front cable from adjuster. Remove cable housing
retainer from anchor bracket, by sliding a 14 mm box
wrench over cable retainer and compressing the three fingers. Alternate method is to use an
aircraft type hose clamp and screwdriver. This is similar to the method shown for removing the
parking brake cable from the support plate.
2. Remove cable guide brackets from frame rail and loosen cable housing at pedal assembly. 3.
Lift floor mat for access to floor pan and force seal out of hole (into vehicle). 4. Pull park brake
cable strand end forward and disconnect button from clevis. Tap cable housing end fitting out of
pedal assembly bracket. 5. Pull park brake cable assembly into vehicle through hole in floor pan.
Install
Parking Brake Removal And Install
1. Pass cable assembly through hole in floor from inside vehicle. 2. Install cable retainer into brake
pedal assembly bracket and then install cable housing end fitting into retainer. 3. Engage cable
strand button into clevis. 4. Install floor pan seal and floor mat. 5. Insert brake cable and housing
into anchor bracket making certain that housing retainer fingers lock the housing firmly into place.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5952
6. Install cable guide brackets. 7. Assemble adjuster to front cable. 8. Adjust parking brake.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5953
Parking Brake Cable: Service and Repair Rear Cable Replacement
REAR PARKING BRAKE CABLE
Remove
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5954
Parking Brake Cable Routing FWD & AWD
1. With vehicle jacked up on suitable hoist remove wheel and tire. 2. Back off cable adjusting nut to
provide slack and disconnect rear cable from equalizer bracket.
Removing Brake Cable From Brake Support Plate
3. To remove cable from anchor bracket. Remove cable housing retainer from anchor bracket by
sliding a 14 mm box wrench over retainer end
compressing the three fingers. Alternate method is to use an aircraft type hose clamp and
screwdriver. This is similar to the method shown for removing the brake cable from the brake
support plate.
4. Remove cable wrap-around clips where applicable. 5. Disconnect cable guide wires where
applicable. 6. Remove brake drum and hub from spindle 7. Disconnect cable from brake internal
lever. 8. Remove park brake cable housing retainer from the brake support plate. Use the same
method for removing cable retainer from brake support plate
as was used above for the cable anchor bracket.
Install
1. Insert park brake cable into hole in the brake support plate. Attach park brake cable to park
brake internal lever attached to brake shoe. 2. Insert cable housing retainer into brake support
plate making certain that cable housing retainer fingers lock the housing and retainer firmly into
place.
3. Install brake drum, wheel and tire. 4. Insert cable housing retainer into anchor bracket making
certain that cable housing retainer fingers lock the housing firmly into place. 5. Attach cable guide
wires and wrap-around clips where applicable. 6. Connect equalizer bracket. 7. Adjust service
brakes and then adjust parking brake.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake
Booster > Component Information > Specifications
Vacuum Brake Booster: Specifications
Master cylinder to brake booster mounting nuts
......................................................................................................................................... 28 Nm (250
in lb) Brake booster assembly to dash panel
........................................................................................................................................................ 28
Nm (250 in lb)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake
Booster > Component Information > Description and Operation > Vacuum Booster Description
Vacuum Brake Booster: Description and Operation Vacuum Booster Description
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake
Booster > Component Information > Description and Operation > Vacuum Booster Description > Page 5961
Vacuum Brake Booster: Description and Operation Vacuum Booster 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake
Booster > Component Information > Service and Repair > Power Brake Unit Service
Vacuum Brake Booster: Service and Repair Power Brake Unit Service
The only serviceable power brake booster components are the vacuum hose and the check valve.
NOTE: The power brake booster must be serviced as an assembly. If diagnosis indicates a power
brake booster fault, the unit must be replaced as an assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake
Booster > Component Information > Service and Repair > Power Brake Unit Service > Page 5964
Vacuum Brake Booster: Service and Repair Vacuum Booster Replacement
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main
Relay > Component Information > Locations
ABS Main Relay: Locations
Fig. 19 Engine Compartment Wiring
Mounted on left fender side shield.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main
Relay > Component Information > Locations > Page 5969
ABS Main Relay: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect wiring harness electrical connectors from relays,
then remove screw securing relay assembly to left front inner fender. 3. Reverse procedure to
install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake
Fluid Pump Relay > Component Information > Locations
Brake Fluid Pump Relay: Locations
Fig. 19 Engine Compartment Wiring
Mounted on left fender side shield.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Diagrams
ABS Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Diagrams > Page 5976
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 information from the wheel speed sensors to control the anti-lock
brake system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Diagrams > Page 5977
Electronic Brake Control Module: Service and Repair
1. With ignition switch in Off position, disconnect both battery cables and remove battery, then
remove battery tray from vehicle. 2. Remove Controller Anti-lock Brake (CAB) from battery tray
support bracket. 3. Loosen bolt securing 60-way connector to CAB, then disconnect connector from
CAB by pulling straight out. Do not twist connector. 4. Remove CAB with its mounting bracket from
vehicle. 5. Reverse procedure to install, noting the following:
a. Ensure ignition switch is still in Off position before connecting 60-way connector to CAB. b.
Torque connector bolt to 38 inch lbs. and CAB assembly mounting bolt to 14 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions
Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number
81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5990
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5991
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5992
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5993
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5994
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5995
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5996
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5997
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5998
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5999
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6000
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6001
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6002
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6003
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6004
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6005
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6006
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6007
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6008
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6009
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6010
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6011
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6012
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6013
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6014
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously
Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 6019
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis
Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed
Sensor Diagnosis
NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994
SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis
MODELS: 1993 - 1994
(AA) Spirit/Acclaim/LeBaron Sedan
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1994 (AP) Shadow/Shadow Convertible/Sundance
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS.
DISCUSSION:
Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection
have been and are continuing to be tested. An unusually large number of these wheel speed
sensors are being found to have no defects.
The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles:
The diagnostic manual MUST be followed without exception. No shortcuts should be used during
the diagnostic procedure.
All diagnostic work Must begin with test "1A".
All diagnostic work MUST end with "VER-1A".
Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as
preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications
Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications
NO.: 05-17-93 Rev. A
GROUP: Brakes
DATE: Dec. 22, 1993
SUBJECT: Left Front Wheel Speed Sensor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991-1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE
SYSTEM (ABS).
DISCUSSION:
On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel,
depending upon the model year. The difference between the two parts is the length of the wiring,
and they should not be interchanged.
P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this
part is used on prior model year vehicles the wiring may become damaged.
P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a **
later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to
the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring.
This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts
catalog bulletin is being developed and the parts catalog will be revised at a later date.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS Warning Light ON Continuously
Wheel Speed Sensor: Customer Interest ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS Warning Light ON Continuously > Page 6033
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions
Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test
Revisions
NUMBER: 26-10-99I
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number
81-699-96026
DESCRIPTION OF CHANGES
Revisions to the ABS test procedures for wheel speed sensors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6039
39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6040
43
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6041
45
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6042
47
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6043
51
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6044
55
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6045
57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6046
59
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6047
63
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6048
67
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6049
69
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6050
71
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6051
173
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6052
177
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6053
179
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6054
181
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6055
187
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6056
191
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6057
193
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6058
195
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6059
201
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6060
205
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6061
207
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6062
209
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6063
256
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis
Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed
Sensor Diagnosis
NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994
SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis
MODELS: 1993 - 1994
(AA) Spirit/Acclaim/LeBaron Sedan
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1994 (AP) Shadow/Shadow Convertible/Sundance
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS.
DISCUSSION:
Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection
have been and are continuing to be tested. An unusually large number of these wheel speed
sensors are being found to have no defects.
The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles:
The diagnostic manual MUST be followed without exception. No shortcuts should be used during
the diagnostic procedure.
All diagnostic work Must begin with test "1A".
All diagnostic work MUST end with "VER-1A".
Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as
preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications
Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications
NO.: 05-17-93 Rev. A
GROUP: Brakes
DATE: Dec. 22, 1993
SUBJECT: Left Front Wheel Speed Sensor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991-1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE
SYSTEM (ABS).
DISCUSSION:
On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel,
depending upon the model year. The difference between the two parts is the length of the wiring,
and they should not be interchanged.
P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this
part is used on prior model year vehicles the wiring may become damaged.
P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a **
later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to
the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring.
This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts
catalog bulletin is being developed and the parts catalog will be revised at a later date.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 6072
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 (V6-201 3.3L (1994))
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
1. Raise and support vehicle, then remove wheel and tire assembly.
Fig. 252 Front Wheel Speed Sensor 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.
NOTE: 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 5 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front > Page 6075
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, noting the following: a. Torque sensor mounting bolt to 5 ft. lbs. b.
Torque U-bolt nuts to 65 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Testing and Inspection
Clutch Switch: Testing and Inspection
Bosch & Nippondenso Starters
The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal
switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal
released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to
floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully
depressed, replace switch if it fails any test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition
Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition
Cylinder Addition
NUMBER: 23-44-94D
GROUP: Body
DATE: Jun. 3, 1994
Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105
DISCUSSION:
A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle
security.
The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a
bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove
the screw.
The 1995 Dakota service manual was completed prior to this information being available to Service
Publications. The vehicles listed as 1994 models only, will have this information already in their
corresponding 1995 service manual.
DESCRIPTION OF CHANGES
Add Tamper Resistant Ignition Key Cylinder Info.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 6086
8D - 37
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 6087
8D - 38
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 6088
8D - 39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition
Cylinder Addition > Page 6089
8D - 39A
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > Customer Interest: > 210294 > Feb > 94 > A/T - Engine
Stalls On Takeoff
Neutral Safety Switch: Customer Interest A/T - Engine Stalls On Takeoff
NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994
SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear
MODELS:
1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town &
Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN
ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES
THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS,
OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED.
SYMPTOM/CONDITION:
While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector
lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the
neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test
when the transmission temperature is -16 F (-27 C) or colder.
DIAGNOSIS:
Determine if the ambient temperature could have been -16 F (-27 C) or colder when the
transmission lever was placed in a forward gear position.
Assure the shift selector is not binding and is adjusted correctly.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic
procedure manual, verify that all 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. If no codes are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4707123 Switch, Neutral/Start (Park/Neutral)
REPAIR PROCEDURE:
NOTE:
THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE
SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID.
This bulletin involves replacing the park/neutral position switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > Customer Interest: > 210294 > Feb > 94 > A/T - Engine
Stalls On Takeoff > Page 6098
1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs.
(34 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210294 > Feb > 94 > A/T
- Engine Stalls On Takeoff
Neutral Safety Switch: All Technical Service Bulletins A/T - Engine Stalls On Takeoff
NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994
SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear
MODELS:
1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town &
Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN
ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES
THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS,
OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED.
SYMPTOM/CONDITION:
While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector
lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the
neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test
when the transmission temperature is -16 F (-27 C) or colder.
DIAGNOSIS:
Determine if the ambient temperature could have been -16 F (-27 C) or colder when the
transmission lever was placed in a forward gear position.
Assure the shift selector is not binding and is adjusted correctly.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic
procedure manual, verify that all 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. If no codes are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4707123 Switch, Neutral/Start (Park/Neutral)
REPAIR PROCEDURE:
NOTE:
THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE
SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID.
This bulletin involves replacing the park/neutral position switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210294 > Feb > 94 > A/T
- Engine Stalls On Takeoff > Page 6104
1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs.
(34 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: >
212493 > Sep > 93 > M/T - Vent Oil Leak
Case: All Technical Service Bulletins M/T - Vent Oil Leak
NO.: 21-24-93 GROUP: Transmission DATE: Sep. 3, 1993
SUBJECT: Oil Leak At Transaxle Vent
MODELS:
1990 - 1993 (AG) Daytona
1990 - 1994 (AA) Spirit/Acclaim (AJ) LeBaron Coupe/LeBaron Convertible (AP) Shadow/Shadow
Convertible/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH MANUAL TRANSAXLE MODELS
A-523, A-543, OR A-568.
SYMPTOM/CONDITION:
Transaxle oil leak on or around selector shaft cover and/or other surrounding surfaces, including
the rear end cover and differential bearing retainer. Oil found to be leaking out of vent cap on
crossover lever.
NOTE:
THIS REPAIR SHOULD BE PREFORMED ON ALL VEHICLES WITH A VENT LEAK. CUSTOMER
VEHICLES THAT ARE IN THE DEALERSHIP FOR ANY OTHER REASON SHOULD ALSO BE
INSPECTED FOR THIS LEAK CONDITION.
PARTS REQUIRED:
1 Vent Adapter 4762499
1 Vent 4505557
REPAIR PROCEDURE:
This bulletin involves installing a remote vent assembly in place of the existing lock pin. Also
included is a new linkage adjusting procedure if needed for future transaxle service.
1. Clean any excess oil from surrounding surfaces.
2. Remove, lock pin located on transaxle selector shaft cover (Figure 1). Discard lock pin.
3. Install vent adapter (P/N 4762499) in selector shaft cover where lock pin was removed. Tighten
to 40 in.lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: >
212493 > Sep > 93 > M/T - Vent Oil Leak > Page 6110
4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs.
NOTE:
IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING
PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN.
1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the
vehicle interior as outlined in the appropriate service manual.
2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure
2).
3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift
lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION:
DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE
ADJUSTING SCREW.
4. Reinstall all hardware removed in Step 1.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs.
FAILURE CODE: 71 - Oil Leak
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: >
212493 > Sep > 93 > M/T - Vent Oil Leak > Page 6116
4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs.
NOTE:
IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING
PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN.
1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the
vehicle interior as outlined in the appropriate service manual.
2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure
2).
3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift
lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION:
DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE
ADJUSTING SCREW.
4. Reinstall all hardware removed in Step 1.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs.
FAILURE CODE: 71 - Oil Leak
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Technical Service Bulletins > Page 6117
Neutral Safety Switch: Locations
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
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 (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6120
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6121
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6122
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6123
Neutral Safety Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Page 6124
Neutral Safety Switch: Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Page 6125
Neutral Safety Switch: Testing and Inspection
The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract
codes.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Page 6126
Neutral Safety Switch: Service and Repair
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6131
In Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6132
Starter Relay: Testing and Inspection
Fig 4 Starter Relay Tests
1. Remove starter relay from relay center. 2. Perform testing procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service
Bulletins > Customer Interest for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank
Battery Cable: Customer Interest Engine Starter - Intermittent No Crank
NO: 08-53-94
GROUP: Electrical
DATE: Oct. 7, 1994
SUBJECT: Intermittent No Crank
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
Engine intermittently will not crank.
DIAGNOSIS:
Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is
not fully seated, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the battery to starter cable terminal insulator at the starter
connection.
1. Record the customers preset radio station selections.
2. Disconnect the ground cable from the battery.
3. Remove the battery to starter cable from the starter.
4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration.
5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the
illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat
flush.
6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service
Bulletins > Customer Interest for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank > Page 6142
7. Connect the ground cable to the battery.
8. Reprogram the customers preset radio stations and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-90-12-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank
Battery Cable: All Technical Service Bulletins Engine Starter - Intermittent No Crank
NO: 08-53-94
GROUP: Electrical
DATE: Oct. 7, 1994
SUBJECT: Intermittent No Crank
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
Engine intermittently will not crank.
DIAGNOSIS:
Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is
not fully seated, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the battery to starter cable terminal insulator at the starter
connection.
1. Record the customers preset radio station selections.
2. Disconnect the ground cable from the battery.
3. Remove the battery to starter cable from the starter.
4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration.
5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the
illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat
flush.
6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank >
Page 6148
7. Connect the ground cable to the battery.
8. Reprogram the customers preset radio stations and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-90-12-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Specifications
Generator: Specifications
Alternator ID.
.......................................................................................................................................................
Output Amps @ 15 Volts, 1250 RPM
4557431 [02] ........................................................................................................................................
..................................................................... 84 [01] 5234031 .............................................................
........................................................................................................................................................ 86
[01] 5234032 ........................................................................................................................................
............................................................................. 90 [01] 5234208 .....................................................
..............................................................................................................................................................
.. 98 [01] 5234033 ................................................................................................................................
................................................................................... 102 [01]
Footnotes:
[01] -- Minimum. [02] -- Bosch alternator.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Diagram Information and Instructions
Generator: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Diagram Information and Instructions > Page 6155
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Diagram Information and Instructions > Page 6156
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Diagram Information and Instructions > Page 6157
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Diagram Information and Instructions > Page 6158
Generator: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Diagram Information and Instructions > Page 6159
Generator: Connector Views
Generator Connections
Generator Connections
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Diagram Information and Instructions > Page 6160
Generator Field Circuit
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Page 6161
Generator: Application and ID
ID No. ..................................................................................................................................................
.................................................... 5234032, 5234033
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Diagrams > Page 6162
Generator: Description and Operation
The main components of the alternator are the rotor, stator, rectifier, end shields and drive pulley.
Direct current is available at the output "B+" terminal.
Alternator output is controlled by voltage regulator circuitry contained within the power and logic
modules of the Engine Controller.
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the
generator fails for any reason, the entire assembly must be replaced.
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a
current into the windings of the stator coil. Once the generator begins producing sufficient current, it
also provides the current needed to energize the rotor.
The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical
system through the generator, battery, and ground terminals.
Noise emitting from the generator may be caused by: Worn, loose or defective bearings
- Loose or defective drive pulley
- Incorrect, worn, damaged or misadjusted drive belt
- Loose mounting bolts
- Misaligned drive pulley
- Defective stator or diode
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes
Generator: Reading and Clearing Diagnostic Trouble Codes
Displaying & Reading Trouble Codes
CHECK ENGINE LAMP
To start the function, cycle ignition switch ON-OFF-ON-OFF-ON within 5 seconds and any stored
fault code will appear. Check engine lamp will display the code by flashing on and off. There is a
short pause between flashes and a longer pause between digits. All codes displayed are 2 digit
numbers with a 4 second pause between codes. The lamp will flash until all codes are displayed
then 55 (end test) will appear.
SCAN TOOL
1. On 1994-95 models, connect DRB test tool or equivalent scan tool, to Diagnostic Link Connector
(DCL) located under the hood. 2. On 1996 models, connect DRB test tool or equivalent scan tool,
to DCL located under the instrument panel. 3. On all models, follow scan tool manufactures
instructions to access Diagnostic Trouble Codes (DTCs).
Clearing Diagnostic Trouble Codes
Diagnostic Trouble Codes (DTCs) may only be cleared with the use of a suitable scan tool.
Follow scan tool manufacturers instructions to clear DTCs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6165
Generator: Component Tests and General Diagnostics
Troubleshooting
Fig 1 Charging System Diagnosis Chart
Alternator Output Wire Resistance Test
TEST PROCEDURE
1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6166
Fig 2 Alternator Output Wire Resistance Test
Fig 3 Alternator Output Wire Resistance Test
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6167
Fig. 4 Alternator Connections (Plug Type)
Fig. 5 Alternator Connections (Nut Type)
6. Connect suitable jumper wire to ground and K20 (field driver) terminal at rear of alternator. This
may generate a fault code. Do not connect
powered field circuit to ground, as component damage will occur.
7. Connect a suitable engine tachometer, then reconnect battery ground cable. 8. Ensure carbon
pile is in OPEN or OFF position, then connect a variable carbon pile rheostat to battery terminals.
9. 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 0.5 volt.
TEST RESULTS
1. If a higher than specified voltage drop is indicated, clean and tighten all connectors in charging
circuit. A voltage drop inspection may be
performed at each connector to locate point of excessive resistance.
2. If charging circuit resistance inspection 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. Erase codes using DRB inspection tool or equivalent scan tool.
Output Current Test
TEST PROCEDURE
1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6168
Fig 6 Alternator Current Output Test
Fig 7 Alternator Current Output Test
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 pile is in Open or Off position.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6169
7. Remove air hose between Engine Controller and air cleaner.
Fig. 4 Alternator Connections (Plug Type)
Fig. 5 Alternator Connections (Nut Type)
8. Connect suitable jumper wire to ground and K20 (field driver) terminal, at rear of alternator. This
may generate a fault code. Do not connect
power field circuit to ground, as component damage will occur.
9. 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 inspection.
TEST RESULTS
1. Note ammeter reading. 2. If reading is less than specified and alternator wire resistance is not
excessive, alternator is defective. 3. After completion of current output inspection, 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 DRB test tool or
equivalent scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Information > Testing and Inspection > Page 6170
Generator: Service and Repair
Fig. 5 Alternator Replacement
1. Disconnect battery ground cable and remove alternator drive belt. 2. Loosen but do not remove
nut on alternator support bracket at exhaust manifold. 3. Remove alternator/tensioner/power
steering bracket bolt, then the tensioner stud nut and tensioner. 4. Remove alternator mounting
bolts, then the power steering reservoir from alternator mounting bracket and position aside. Do not
remove power
steering hoses from reservoir.
5. Remove three alternator support bracket bolts, then the intake plenum to alternator mounting
bracket bolt. 6. Remove alternator support bracket, then the alternator electrical wiring. 7. Remove
alternator from vehicle. 8. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing
and Inspection
Clutch Switch: Testing and Inspection
Bosch & Nippondenso Starters
The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal
switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal
released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to
floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully
depressed, replace switch if it fails any test.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical
Service Bulletins > Tamper Resistant Ignition Key Cylinder - Revision
Ignition Lock: Technical Service Bulletins Tamper Resistant Ignition Key Cylinder - Revision
NO: 23-44-94
GROUP: Body
DATE: Jun. 3, 1994
SUBJECT: Service Manual Correction Tamper Resistant Ignition Key Cylinder
MODELS:
1994 (AA) Spirit/Acclaim/LeBaron Sedan (Built after 3/16/94 MDH 0316XX)
1994 (AB) Ram Van/Wagon (Built after 3/10/94 MDH 0310XX)
1994 (AJ) LeBaron Convertible (Built after 3/16/94 MDH 0316XX)
1994 - 1995 (AN) Dakota/Dakota Cab & Chassis (Built after 3/14/94 MDH 0314XX)
1994 (AS) Caravan/Voyager/Town & Country (Built after 3/28/94 MDH 0328XX)
1994 (BR) Ram Pickup (Built after 3/14/94 MDH 0314XX)
1994 (ZJ) Grand Cherokee (Built after 3/10/94 MDH 0310XX)
DISCUSSION:
A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle
security.
The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a
bracket, refer to the illustration. A Snap-On TTXR2OA2 torx-bit or equivalent is required to remove
the screw.
The 1995 Dakota service manual was completed prior to this information being available to Service
Publications. The vehicles listed as 1994 models only, will have this information already in their
corresponding 1995 service manual.
This technical service bulletin contains revised service manual pages.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical
Service Bulletins > Tamper Resistant Ignition Key Cylinder - Revision > Page 6179
Please insert the revised service manual pages in the appropriate service manual.
NOTE:
THE REVISION PAGES ARE REDUCED IN SIZE TO ACCOMMODATE PLACEMENT OVER THE
EXISTING PAGE. TWO SIDED TAPE IS ALSO APPLIED TO MAKE INSERTION INTO THE
MANUAL PERMANENT.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition
Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition
Cylinder Addition
NUMBER: 23-44-94D
GROUP: Body
DATE: Jun. 3, 1994
Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105
DISCUSSION:
A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle
security.
The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a
bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove
the screw.
The 1995 Dakota service manual was completed prior to this information being available to Service
Publications. The vehicles listed as 1994 models only, will have this information already in their
corresponding 1995 service manual.
DESCRIPTION OF CHANGES
Add Tamper Resistant Ignition Key Cylinder Info.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6185
8D - 37
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6186
8D - 38
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6187
8D - 39
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6188
8D - 39A
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On
Takeoff
Neutral Safety Switch: Customer Interest A/T - Engine Stalls On Takeoff
NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994
SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear
MODELS:
1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town &
Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN
ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES
THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS,
OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED.
SYMPTOM/CONDITION:
While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector
lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the
neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test
when the transmission temperature is -16 F (-27 C) or colder.
DIAGNOSIS:
Determine if the ambient temperature could have been -16 F (-27 C) or colder when the
transmission lever was placed in a forward gear position.
Assure the shift selector is not binding and is adjusted correctly.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic
procedure manual, verify that all 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. If no codes are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4707123 Switch, Neutral/Start (Park/Neutral)
REPAIR PROCEDURE:
NOTE:
THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE
SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID.
This bulletin involves replacing the park/neutral position switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On
Takeoff > Page 6197
1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs.
(34 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine
Stalls On Takeoff
Neutral Safety Switch: All Technical Service Bulletins A/T - Engine Stalls On Takeoff
NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994
SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear
MODELS:
1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker
Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town &
Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN
ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES
THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS,
OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED.
SYMPTOM/CONDITION:
While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector
lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the
neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test
when the transmission temperature is -16 F (-27 C) or colder.
DIAGNOSIS:
Determine if the ambient temperature could have been -16 F (-27 C) or colder when the
transmission lever was placed in a forward gear position.
Assure the shift selector is not binding and is adjusted correctly.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic
procedure manual, verify that all 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. If no codes are present and all systems are functioning correctly, proceed with the
following repair.
PARTS REQUIRED:
1 4707123 Switch, Neutral/Start (Park/Neutral)
REPAIR PROCEDURE:
NOTE:
THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE
SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID.
This bulletin involves replacing the park/neutral position switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine
Stalls On Takeoff > Page 6203
1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs.
(34 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Page 6204
Neutral Safety Switch: Locations
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
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 (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6207
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6208
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6209
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6210
Neutral Safety Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Page 6211
Neutral Safety Switch: Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Page 6212
Neutral Safety Switch: Testing and Inspection
The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract
codes.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Page 6213
Neutral Safety Switch: Service and Repair
Transmission Range Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.).
Park/Neutral Position Switch
The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34
Nm (25 ft. lbs.).
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank
Starter Motor: Customer Interest Engine Starter - Intermittent No Crank
NO: 08-53-94
GROUP: Electrical
DATE: Oct. 7, 1994
SUBJECT: Intermittent No Crank
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
Engine intermittently will not crank.
DIAGNOSIS:
Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is
not fully seated, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the battery to starter cable terminal insulator at the starter
connection.
1. Record the customers preset radio station selections.
2. Disconnect the ground cable from the battery.
3. Remove the battery to starter cable from the starter.
4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration.
5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the
illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat
flush.
6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank >
Page 6222
7. Connect the ground cable to the battery.
8. Reprogram the customers preset radio stations and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-90-12-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No
Crank
Starter Motor: All Technical Service Bulletins Engine Starter - Intermittent No Crank
NO: 08-53-94
GROUP: Electrical
DATE: Oct. 7, 1994
SUBJECT: Intermittent No Crank
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
Engine intermittently will not crank.
DIAGNOSIS:
Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is
not fully seated, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the battery to starter cable terminal insulator at the starter
connection.
1. Record the customers preset radio station selections.
2. Disconnect the ground cable from the battery.
3. Remove the battery to starter cable from the starter.
4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration.
5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the
illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat
flush.
6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No
Crank > Page 6228
7. Connect the ground cable to the battery.
8. Reprogram the customers preset radio stations and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-90-12-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Page 6229
Starter Motor: Specifications
Torque
- Starter Mounting Bolts
............................................................................................................................................................
54 N.m (40 ft. lbs.)
- Starter Solenoid Battery Nut
................................................................................................................................................... 10
N.m (90 in. lbs.)
Make ....................................................................................................................................................
............................................................. Nippondenso ID. No. .............................................................
..............................................................................................................................................................
...... -- Type ..........................................................................................................................................
.................................................................... Gear Reduction Power Rating, Kw .................................
..............................................................................................................................................................
.............. 1.2 Free Speed Test
Amps [01] ............................................................................................................................................
.................................................................... 73 Volts ...........................................................................
.............................................................................................................................................. 11 RPM
[02] .......................................................................................................................................................
...................................................... 3401
Cranking Amp Draw Test [03] .............................................................................................................
.................................................................... 150-200
No of fields ...........................................................................................................................................
............................................................................... 4 No of Poles .......................................................
..............................................................................................................................................................
...... 4 Brushes .....................................................................................................................................
............................................................................................ 4 Drive ....................................................
...........................................................................................................................................
Conventional Gear Train
Footnotes: [01] -- Maximum. [02] -- Minimum. [03] -- With engine at operating temperature.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Page 6230
Starter Motor: Application and ID
Make ....................................................................................................................................................
............................................................. Nippondenso ID. No. .............................................................
..............................................................................................................................................................
...... -- Type ..........................................................................................................................................
.................................................................... Gear Reduction
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Page 6231
Starter Motor: Description and Operation
The Nippondenso starters are reduction gear field coil units; Bosch permanent magnet reduction
gear starters contain a planetary gear train which transmits power between the starter motor and its
pinion shaft.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing
and Inspection > Troubleshooting
Starter Motor: Testing and Inspection Troubleshooting
Fig 1 Starter Motor Troubleshooting
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing
and Inspection > Troubleshooting > Page 6234
Fig 2 Starting System Components
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing
and Inspection > Troubleshooting > Page 6235
Starter Motor: Testing and Inspection Diagnosis and Testing
Starter Feed Circuit Tests
1. Disable ignition system on gasoline engines or fuel system on diesel engines. 2. Connect
volt/ampere tester to battery terminals. Refer to operating instructions provided with tester being
used. 3. Verify that all lights and accessories are Off and transmission shift selector is in Park for
automatic transmissions/transaxles or Neutral for manual
transmissions/transaxles, then set parking brake.
4. Hold ignition switch in Start position. Observe tester.
a. If voltage reads above 9.6 volts and amperage draw reads above 250 amps, proceed to starter
feed circuit resistance test. b. If voltage reads 12.4 volts or greater and amperage reads 0-10
amps, proceed to starter control circuit test. c. If starter motor turns engine freely at times, but
starting system is still suspected, engage starter several times while observing tester. A starting
system that has a problem should fail while performing this procedure.
5. After starting system problem have been corrected, verify battery state of charge, disconnect all
testing equipment and connect distributor.
Starter Feed Circuit Resistance Test
The following test will require a voltmeter accurate to 0.1 volt.
1. Disable ignition system on gasoline engines or fuel system on diesel engines. 2. With all wiring
harness and components connected properly, perform the following:
a. Connect positive lead of voltmeter to battery negative post, and negative lead to battery negative
cable clamp. Rotate and hold ignition switch
in Start position. Observe voltmeter. If voltage is not detected, correct poor contact between cable
clamp and post.
b. Connect positive lead of voltmeter to battery positive post, and negative lead to battery cable
positive clamp. Rotate and hold ignition switch in
Start position. Observe voltmeter. If voltage is not detected, correct poor contact between cable
clamp and post.
c. Connect positive lead of voltmeter to battery negative terminal, and negative led to engine block
near battery cable attaching point.
3. Rotate and hold ignition switch in Start position. If voltage reads above 0.2 volt, correct poor
contact at ground cable attaching point. If reading is
still above 0.2 volt, replace ground cable.
4. Remove starter heat shield (if equipped), then perform the following:
a. Connect positive voltmeter lead to starter motor housing and negative lead to battery negative
terminal. Rotate and hold ignition switch in Start
position. If voltage reads above 0.2 volt, correct poor starter to engine ground.
b. Connect positive voltmeter lead to positive battery terminal and negative lead to battery cable
terminal on starter solenoid. Rotate and hold
ignition switch in Start position. If voltage reads above 0.2 volt, correct poor contact at battery cable
to solenoid connection. If reading is still above 0.2 volt, replace positive battery cable.
5. If resistance tests detect no feed circuit failures, remove starter motor and proceed to "Starter
Solenoid Bench Test."
Starter Control Circuit Test Notes
The starter control circuit consists of a starter solenoid, starter relay, ignition switch and clutch
pedal interlock switch (manual transmission) or neutral safety switch (automatic transmission).
Disable ignition system on gasoline engines or fuel system on diesel engines prior to performing
test procedures.
Solenoid Test
1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. If engine
cranks, perform starter relay test. 2. If engine does not crank or solenoid chatters, check wiring and
connectors from relay to starter for loose or corroded connections. 3. Repeat test and, if engine still
does not crank properly, repair or replace starter as necessary.
Starter Relay Test
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing
and Inspection > Troubleshooting > Page 6236
Fig 4 Starter Relay Tests
1. Remove starter relay from relay center. 2. Perform testing procedure.
Clutch Pedal Switch
The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal
switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal
released, there should be no continuity.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing
and Inspection > Troubleshooting > Page 6237
3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity.
4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test.
Starter Solenoid Bench Test
Fig 6 Bosch Starter Solenoid Terminal Identification
Fig 7 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing
and Inspection > Page 6238
Starter Motor: Service and Repair
1. Disconnect battery ground cable, then raise and support vehicle. 2. Remove starter motor
attaching bolts and nuts. 3. Disconnect all electrical connectors from starter motor and remove
starter. 4. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 6242
In Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 6243
Starter Relay: Testing and Inspection
Fig 4 Starter Relay Tests
1. Remove starter relay from relay center. 2. Perform testing procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Testing and Inspection > Solenoid Test
Starter Solenoid: Testing and Inspection Solenoid Test
1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. If engine
cranks, perform starter relay test. 2. If engine does not crank or solenoid chatters, check wiring and
connectors from relay to starter for loose or corroded connections. 3. Repeat test and, if engine still
does not crank properly, repair or replace starter as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Testing and Inspection > Solenoid Test > Page 6248
Starter Solenoid: Testing and Inspection Starter Solenoid Bench Test
Fig 6 Bosch Starter Solenoid Terminal Identification
Fig 7 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations
Power Distribution Center: Locations
Relay Locations
Relays mounted under hood on driver's side fender well.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions
Power Distribution Center: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6255
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6256
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6257
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6258
Power Distribution Center: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6259
Power Distribution Center: Electrical Diagrams
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6260
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6261
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6262
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6263
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6264
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6265
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6266
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center
Fuse: Locations Power Distribution Center
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6271
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6272
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6273
Fuse: Locations Fuse Block Module
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6274
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6277
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6278
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6279
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6280
Fuse: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6281
Fuse: Electrical Diagrams
Fuse Application Chart (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6282
Fuse Application Chart (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6283
Fuse Application Chart (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6284
Fuse Application Chart (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Page 6285
Fuse: Service Precautions
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle
in Lower Left Dash Area
Fuse Block: Customer Interest Fuse Block - Rattle in Lower Left Dash Area
NO.: 08-46-93 Rev. A
GROUP: Electrical
DATE: Dec. 17, 1993
SUBJECT: Fuse Block Mounting Tabs Cracked
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION
THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL
THEM.
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006).
SYMPTOM/CONDITION:
A rattle may be heard at the lower left area of the instrument panel. This condition can be caused
by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket.
DIAGNOSIS:
Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered,
perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to
20 In.Lbs. (2.3 N-m).
PARTS REQUIRED:
1 4773171 Bracket
1 4773172 Bracket
REPAIR PROCEDURE:
This bulletin involves installing revised fuse block mounting brackets.
1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering
column cover.
2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing.
3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle
in Lower Left Dash Area > Page 6294
4. Using the two screws that attached the original bracket to the fuse block, assemble the service
brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the
screws to 20 In.Lbs. (2.3 N-m).
6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to
20 In.Lbs. (2.3 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 08-90-90-92 0.3 Hrs.
FAILURE CODE: 11 - Broken or Cracked
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse
Block - Rattle in Lower Left Dash Area
Fuse Block: All Technical Service Bulletins Fuse Block - Rattle in Lower Left Dash Area
NO.: 08-46-93 Rev. A
GROUP: Electrical
DATE: Dec. 17, 1993
SUBJECT: Fuse Block Mounting Tabs Cracked
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION
THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL
THEM.
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006).
SYMPTOM/CONDITION:
A rattle may be heard at the lower left area of the instrument panel. This condition can be caused
by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket.
DIAGNOSIS:
Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered,
perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to
20 In.Lbs. (2.3 N-m).
PARTS REQUIRED:
1 4773171 Bracket
1 4773172 Bracket
REPAIR PROCEDURE:
This bulletin involves installing revised fuse block mounting brackets.
1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering
column cover.
2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing.
3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse
Block - Rattle in Lower Left Dash Area > Page 6300
4. Using the two screws that attached the original bracket to the fuse block, assemble the service
brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the
screws to 20 In.Lbs. (2.3 N-m).
6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to
20 In.Lbs. (2.3 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 08-90-90-92 0.3 Hrs.
FAILURE CODE: 11 - Broken or Cracked
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Technical Service Bulletins > Page 6301
Fuse Block: Locations
Fuse panel is located below left side of instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6304
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6305
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6306
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6307
Fuse Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6308
Fuse Block: Electrical Diagrams
Fuse Application Chart (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6309
Fuse Application Chart (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6310
Fuse Application Chart (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6311
Fuse Application Chart (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6312
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6313
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6314
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6315
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6316
Fuse Block: Mechanical Diagrams
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6317
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6318
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6319
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 6320
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component
Information > Service and Repair
Fusible Link: Service and Repair
Purpose
Fusible links protect vehicle electrical systems from damage due to excessive current.
^ The most common cause of excessive current is a short to ground caused by a component or
wiring failure.
Fusible links are color coded to indicate wire gauge and size.
Fig. 9 Fusible Link Chart
CAUTION:
Replace blown fusible links with correct gauge, hypalon insulated, fusible type wire ONLY.
^ Use of standard wire may result in severe damage to the electrical system or an electrical fire.
NOTE: Refer to the fusible link chart and the wiring diagrams for proper color and gauge
identification.
Replacement
Splicing Wires
CAUTION: If a fusible link has blown, find the cause before attempting to replace the link.
NOTE: If a faulty fusible link is suspected, it is important to carefully check the link for continuity
over its entire length. In some instances the link may look fine and actually be blown.
1. Disconnect battery negative cable.
2. Cut out the blown portion of the fusible link.
3. Strip 1 inch of insulation from each end of the existing fusible link.
4. Place a piece of heat shrink tubing long enough to cover and seal the entire repair area over one
side of the fusible link.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component
Information > Service and Repair > Page 6324
5. Cut a replacement piece of fusible link approximately two inches longer than the piece removed.
6. Remove one inch of insulation from each end of the replacement fusible link.
7. Spread the stripped ends of the wires apart (example 1).
8. Push the stripped ends of the wires together until the cut ends almost touch the insulation of the
other wire (example 2).
9. Twist the wires together (example 3).
10. Solder the wires together using rosin core type solder only. Never use acid core type solder for
soldering electrical/electronic connections.
11. Center the heat shrink tubing over the joint. Heat the joint with a heat gun until the tubing is
tightly sealed and sealant is coming out of both ends of the tubing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center
Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center
Location > Page 6330
Micro Relay Block: Locations Power Distribution Center Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center
Location > Page 6331
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center
Location > Page 6332
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center
Location > Page 6333
Micro Relay Block: Locations Micro Relay Block and Relay Bank Location
Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of
instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions
Micro Relay Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6336
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6337
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6338
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6339
Micro Relay Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6340
Micro Relay Block: Connector Views
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6341
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6342
Micro Relay Block: Electrical Diagrams
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6343
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6344
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and
Instructions > Page 6345
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Locations > Power Distribution Center Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Locations > Power Distribution Center Location > Page 6350
Micro Relay Block: Locations Power Distribution Center Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Locations > Power Distribution Center Location > Page 6351
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Locations > Power Distribution Center Location > Page 6352
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Locations > Power Distribution Center Location > Page 6353
Micro Relay Block: Locations Micro Relay Block and Relay Bank Location
Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of
instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions
Micro Relay Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6356
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6357
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6358
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6359
Micro Relay Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6360
Micro Relay Block: Connector Views
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6361
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6362
Micro Relay Block: Electrical Diagrams
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6363
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6364
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6365
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Locations
Power Distribution Center: Locations
Relay Locations
Relays mounted under hood on driver's side fender well.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions
Power Distribution Center: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6372
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6373
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6374
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6375
Power Distribution Center: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6376
Power Distribution Center: Electrical Diagrams
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6377
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6378
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6379
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6380
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6381
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6382
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6383
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center
Fuse: Locations Power Distribution Center
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6388
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6389
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6390
Fuse: Locations Fuse Block Module
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6391
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions
Fuse: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6394
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6395
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6396
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6397
Fuse: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6398
Fuse: Electrical Diagrams
Fuse Application Chart (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6399
Fuse Application Chart (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6400
Fuse Application Chart (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6401
Fuse Application Chart (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 6402
Fuse: Service Precautions
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service
Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area
Fuse Block: Customer Interest Fuse Block - Rattle in Lower Left Dash Area
NO.: 08-46-93 Rev. A
GROUP: Electrical
DATE: Dec. 17, 1993
SUBJECT: Fuse Block Mounting Tabs Cracked
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION
THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL
THEM.
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006).
SYMPTOM/CONDITION:
A rattle may be heard at the lower left area of the instrument panel. This condition can be caused
by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket.
DIAGNOSIS:
Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered,
perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to
20 In.Lbs. (2.3 N-m).
PARTS REQUIRED:
1 4773171 Bracket
1 4773172 Bracket
REPAIR PROCEDURE:
This bulletin involves installing revised fuse block mounting brackets.
1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering
column cover.
2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing.
3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service
Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area > Page
6411
4. Using the two screws that attached the original bracket to the fuse block, assemble the service
brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the
screws to 20 In.Lbs. (2.3 N-m).
6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to
20 In.Lbs. (2.3 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 08-90-90-92 0.3 Hrs.
FAILURE CODE: 11 - Broken or Cracked
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash
Area
Fuse Block: All Technical Service Bulletins Fuse Block - Rattle in Lower Left Dash Area
NO.: 08-46-93 Rev. A
GROUP: Electrical
DATE: Dec. 17, 1993
SUBJECT: Fuse Block Mounting Tabs Cracked
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION
THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL
THEM.
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006).
SYMPTOM/CONDITION:
A rattle may be heard at the lower left area of the instrument panel. This condition can be caused
by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket.
DIAGNOSIS:
Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered,
perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to
20 In.Lbs. (2.3 N-m).
PARTS REQUIRED:
1 4773171 Bracket
1 4773172 Bracket
REPAIR PROCEDURE:
This bulletin involves installing revised fuse block mounting brackets.
1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering
column cover.
2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing.
3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash
Area > Page 6417
4. Using the two screws that attached the original bracket to the fuse block, assemble the service
brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the
screws to 20 In.Lbs. (2.3 N-m).
6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to
20 In.Lbs. (2.3 N-m).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 08-90-90-92 0.3 Hrs.
FAILURE CODE: 11 - Broken or Cracked
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service
Bulletins > Page 6418
Fuse Block: Locations
Fuse panel is located below left side of instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6421
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6422
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6423
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6424
Fuse Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6425
Fuse Block: Electrical Diagrams
Fuse Application Chart (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6426
Fuse Application Chart (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6427
Fuse Application Chart (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6428
Fuse Application Chart (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6429
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6430
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6431
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6432
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6433
Fuse Block: Mechanical Diagrams
Fig. 16 Fuse Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6434
Fuseblock Module (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6435
Fuseblock Module (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6436
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6437
Power Distribution Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Service and Repair
Fusible Link: Service and Repair
Purpose
Fusible links protect vehicle electrical systems from damage due to excessive current.
^ The most common cause of excessive current is a short to ground caused by a component or
wiring failure.
Fusible links are color coded to indicate wire gauge and size.
Fig. 9 Fusible Link Chart
CAUTION:
Replace blown fusible links with correct gauge, hypalon insulated, fusible type wire ONLY.
^ Use of standard wire may result in severe damage to the electrical system or an electrical fire.
NOTE: Refer to the fusible link chart and the wiring diagrams for proper color and gauge
identification.
Replacement
Splicing Wires
CAUTION: If a fusible link has blown, find the cause before attempting to replace the link.
NOTE: If a faulty fusible link is suspected, it is important to carefully check the link for continuity
over its entire length. In some instances the link may look fine and actually be blown.
1. Disconnect battery negative cable.
2. Cut out the blown portion of the fusible link.
3. Strip 1 inch of insulation from each end of the existing fusible link.
4. Place a piece of heat shrink tubing long enough to cover and seal the entire repair area over one
side of the fusible link.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Service and Repair
> Page 6441
5. Cut a replacement piece of fusible link approximately two inches longer than the piece removed.
6. Remove one inch of insulation from each end of the replacement fusible link.
7. Spread the stripped ends of the wires apart (example 1).
8. Push the stripped ends of the wires together until the cut ends almost touch the insulation of the
other wire (example 2).
9. Twist the wires together (example 3).
10. Solder the wires together using rosin core type solder only. Never use acid core type solder for
soldering electrical/electronic connections.
11. Center the heat shrink tubing over the joint. Heat the joint with a heat gun until the tubing is
tightly sealed and sealant is coming out of both ends of the tubing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6447
Micro Relay Block: Locations Power Distribution Center Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6448
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6449
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6450
Micro Relay Block: Locations Micro Relay Block and Relay Bank Location
Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of
instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions
Micro Relay Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6453
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6454
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6455
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6456
Micro Relay Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6457
Micro Relay Block: Connector Views
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6458
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6459
Micro Relay Block: Electrical Diagrams
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6460
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6461
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6462
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Locations > Power Distribution Center Location
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Locations > Power Distribution Center Location > Page 6467
Micro Relay Block: Locations Power Distribution Center Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Locations > Power Distribution Center Location > Page 6468
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Locations > Power Distribution Center Location > Page 6469
Fig. 17 Relay Bank Identification
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Locations > Power Distribution Center Location > Page 6470
Micro Relay Block: Locations Micro Relay Block and Relay Bank Location
Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of
instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions
Micro Relay Block: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6473
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6474
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6475
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6476
Micro Relay Block: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6477
Micro Relay Block: Connector Views
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6478
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6479
Micro Relay Block: Electrical Diagrams
Power Distribution Center (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6480
Power Distribution Center (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6481
Power Distribution Center (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information
> Diagrams > Diagram Information and Instructions > Page 6482
Power Distribution Center (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front
Alignment Specifications
Alignment: Specifications Front Alignment Specifications
Caster, Degrees ..................................................................................................................................
.................................................................... +1.3 [01] Camber, Degrees ............................................
..............................................................................................................................................................
.... 0.3 Toe-In, Inch ..............................................................................................................................
..................................................................................... 1/16 Ball Joint Wear ......................................
..............................................................................................................................................................
........... [03]
[01] -- Reference angle only, not adjustable.
[03] -- Refer to Ball Joint Inspection in Front Steering & Suspension section.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front
Alignment Specifications > Page 6488
Alignment: Specifications Rear Alignment Specifications
Caster, Degrees ..................................................................................................................................
.................................................................................. -- Camber, Degrees ..........................................
..............................................................................................................................................................
...... -0.2 Toe-In, Inch ...........................................................................................................................
....................................................................................... 0 [01] Ball Joint Wear ..................................
..............................................................................................................................................................
................ [04]
[01] -- Toe-out when vehicle is backed onto alignment rack is toe-in when driving.
[04] -- Refer to Ball Joint Inspection in Rear Steering & Suspension section.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front
Alignment
Alignment: Service and Repair Front Alignment
Adjustment
CASTER
The caster angle on these vehicles cannot be adjusted.
Fig. 1 Camber Adjustment
CAMBER
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.
Fig. 2 Toe-in Adjustment
TOE-IN
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front
Alignment > Page 6491
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.
Preliminary Inspection
1. Tires are at recommended pressure, are of equal size and have approximately the same wear
pattern 2. Check front wheel and tire assembly for radial runout and inspect lower ball joints and
steering linkage for looseness. 3. Check front and rear springs for sagging or damage. 4. 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.
5. Prior to each alignment reading, vehicle should be bounced an equal number of times from
center of the bumper alternating first from rear, then
front, and releasing at bottom of down cycle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front
Alignment > Page 6492
Alignment: Service and Repair Rear Alignment
FWD MODELS
Fig. 3 Shim Installation For Toe-out (FWD)
Fig. 4 Shim Installation For Toe-in (FWD)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front
Alignment > Page 6493
Fig. 5 Shim Installation For Positive Camber (FWD)
Fig. 6 Shim Installation For Negative Camber (FWD)
Alignment adjustment is made by adding .010 inch shims between spindle mounting surface and
axle casting. Each shim equals wheel change by 0.3.°
When recording rear toe-in (vehicle backed onto alignment rack) remember to reverse sign
convention. Install alignment shims as follows; 1. Raise and support vehicle, then remove wheel. 2.
Remove brake drum, then loosen four brake assembly and spindle mounting bolts enough to allow
clearance for shim installation. Do not remove
mounting bolts.
3. Install shims as shown. No more than 2 shims on each spindle should be used to bring
alignment within acceptable range.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component
Information > Service and Repair
Ball Stud: Service and Repair
Fig. 18 Steering Knuckle Assembly
REMOVAL
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied.
NOTE:
Hub and driveshaft are splined together through knuckle (bearing) and retained by 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 CV 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
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 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:
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications
Power Steering Pump: Specifications
Power Steering Specifications Part 1 Of 2
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 6502
Power Steering Specifications Part 2 Of 2
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Description and Operation > Vane Type Power Steering Pump W/Integral Reservoir
Power Steering Pump: Description and Operation Vane Type Power Steering Pump W/Integral
Reservoir
DESCRIPTION
The hydraulic pump is a submerged, vane-type design. Submerged pumps have a housing and
internal parts inside the reservoir and operate submerged in fluid.
OPERATION
There are two openings at the rear of the pump housing. The larger opening contains the cam ring,
pressure plate, thrust plate, rotor and vane assembly and the end plate. The smaller opening
contains the pressure line union, flow control valve, and spring. The flow control orifice is part of the
pressure line union. The pressure relief valve, located inside the flow control valve, limits pump
pressure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Description and Operation > Vane Type Power Steering Pump W/Integral Reservoir > Page 6505
Power Steering Pump: Description and Operation Vane Type Power Steering Pump Less Integral
Reservoir
DESCRIPTION
The hydraulic pump is a non-submerged vane-type design. The housing and internal parts are
separate from the reservoir and are not submerged in fluid.
OPERATION
There are two bore openings at the rear of the pump housing. The larger opening contains the cam
ring, pressure plate, thrust plate, rotor and vane assembly, and end plate. The smaller opening
contains the pressure line union, flow control valve and spring. The pressure relief valve inside the
flow control valve limits pump pressure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Testing and Inspection > Excessive Steering Wheel Play
Power Steering Pump: Testing and Inspection Excessive Steering Wheel Play
1. Excessive play in steering gearbox. 2. Loose steering gear. 3. Loose or worn tie rod end stud.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6508
Power Steering Pump: Testing and Inspection Hard Steering Wheel Operation
1. Air in fluid line. 2. Loose or damaged belt. 3. Low or leaking fluid. 4. Twisted or damaged power
steering hoses. 5. Gearbox or pump malfunction.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6509
Power Steering Pump: Testing and Inspection Noisy Operation
1. Loose oil pump or gearbox. 2. Loose pulley nut. 3. Interference between pressure hose and
other parts. 4. Air entering oil pump. 5. Pump seizure. 6. Loose belt. 7. Gearbox port section
damage. 8. Return hose malfunction. 9. Loose oil pump or pump bracket.
10. Excessive oil pump body wear. 11. Malfunctioning steering stopper. 12. Wheel and tire to body
interference. 13. Malfunctioning gearbox.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6510
Power Steering Pump: Testing and Inspection Oil Leaks
Pump Oil Leak Checking. Saginaw Submerged Vane Pump W/intregal Reservoir (P Type)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6511
Pump Oil Leak Checking. Saginaw Vane Pump W/external Reservoir (TC Type)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul
Power Steering Pump: Service and Repair Power Steering Pump Overhaul
Vane Type Power Steering Pump w/ Integral Reservoir
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6514
DISASSEMBLE
NOTE: Before disassembly of pump, remove filler cap and drain fluid. If broken components or
foreign materials are found during disassembly, hydraulic system should be disassembled,
inspected, cleaned and flushed before servicing is complete.
1. Clean exterior of pump with solvent and crocus cloth. 2. Remove bolt and fitting from rear of
pump reservoir, then the reservoir and seals. 3. Remove end plate retaining ring using a
screwdriver and punch. 4. Remove endplate and pressure plate spring, then the O-ring, control
valve and control valve spring by inverting housing. 5. Tap lightly on driveshaft with a rubber mallet
to remove pressure plate. 6. Pull out pump ring and vanes, then remove shaft retaining ring, pump
rotor and thrust plate. 7. Remove driveshaft key from slot in shaft, then with end of shaft pointed
downward, press down until shaft is free. 8. Remove seals, dowel pins and O-rings.
INSPECTION
1. Clean all parts with solvent and blow dry. 2. Check vane tips for scoring or wear. Vanes must fit
snugly but slide freely in slots of rotor. Examine rotor slots for burrs and excessive wear at
thrust faces.
3. Check inner surface of pump ring for scoring or wear and thrust plate and pressure plate for
wear on plate surfaces. 4. If heavy wear is evident in any of above components, replace entire
rotating group. 5. Inspect seal for leakage, cracking or swelling, if evident replace seal. 6. Check
driveshaft for excessive burning or scoring. 7. Control valve must move smoothly in the valve bore.
ASSEMBLE
1. Lubricate O-rings, pump ring, rotor and vanes with power steering fluid. 2. Install O-rings and
dowel pins on pump housing. 3. Using a seal installation tool, insert seal into front of housing. 4.
Install driveshaft and thrust plate. Ensure counterbore faces driveshaft end of housing and install
rotor. 5. Insert vanes into rotor, ensuring rounded edge faces away from rotor. 6. Install shaft
retaining ring, pump ring and pressure plate.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6515
7. Insert control valve spring, then install control valve and O-ring. 8. Install pressure plate spring
and end plate, then secure with end plate retaining ring. 9. Connect seal and reservoir, then install
bolt and fitting
TC Series
DISASSEMBLE
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6516
Prior to disassembly of the pump, remove filler cap and drain fluid. If broken components or foreign
materials are found during disassembly, then the hydraulic system should be disassembled,
inspected, cleaned and flushed before service is complete.
1. Clean exterior of pump with solvent, then clamp front hub of pump into a soft jaw vise.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6517
2. Pry tab and slide retaining clip off of pump. 3. Remove reservoir, then return tube as follows:
a. Install five 5/8 inch washers and a 9/16-12 nut outside of tube. b. Plug tube to prevent chips from
entering, then insert a 9/16-12 tap into return tube and turn until tube is pulled out of housing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6518
4. Remove O-ring, fitting, O-ring seal, flow control valve and spring.
5. Using snap ring pliers, remove retaining ring. Note position of large lug in housing before
removal.
6. Remove driveshaft and bearing. Note and measure any clearance between collar and shaft.
Press bearing from shaft using a support ring under
bearing.
7. Remove driveshaft seal by prying seal loose with a screwdriver.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6519
8. Insert a punch into access hole, then pry retaining ring loose with a screwdriver.
9. Using a 5/16 inch piece of bar stock or a suitable brass drift, remove thrust plate.
10. Remove pump ring, rotor, vanes and dowel pins. 11. Remove pressure plate and O-ring, then
the spring, seal and remaining dowel pin. 12. Using a suitable punch, remove sleeve assembly.
INSPECTION
1. Clean all parts with solvent and blow dry. 2. Inspect rotating components as follows:
a. Vane tips for scoring or wear. b. Fit of vanes in rotor. Vanes must fit properly in slots without
sticking or excessive play. c. Rotor slots for burrs and excessive wear at thrust faces. d. Inner
surface of pump ring for scoring or wear. e. Thrust plate and pressure plate for wear on plate
surfaces. f.
If heavy wear is present, or parts are faulty, replace entire rotating group.
3. Inspect bearing for rough or looseness and bearing seal for leakage, cracking or swelling. 4.
Check driveshaft and bearing bore for excessive burning or scoring. 5. Control valve must move
smoothly in the valve bore.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6520
ASSEMBLE
1. Press sleeve into housing using a suitable socket and press.
2. Install dowel pin, seal and pressure plate spring.
3. Install O-ring seal, pressure plate and dowel pins. Mark top of pressure plate where pin enters
from underneath to ease alignment with dowel pin
during assembly.
4. Lubricate O-ring, pump ring, rotor and vanes with power steering fluid. Install vanes and rotor
with rounded edge facing away from rotor. Ensure
counterbore of rotor faces driveshaft end of housing.
5. Install pump ring with identification marks facing up, then install O-ring seal and thrust plate.
Thrust plate dimples must line up with bolt holes in
housing and plate must engage pump ring dowel pins.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6521
6. Using a press to compress thrust plate, install retaining plate with the center opening of ring with
bolt hole nearest the access hole. 7. Using a suitable socket and press, install driveshaft seal into
housing until it bottoms. 8. Install bearing onto driveshaft, then slide assembly into housing while
rotating driveshaft so shaft serrations engage with rotor. 9. Insert retaining ring ensuring large tab
of ring is properly located. Refer to.
10. Install flow control spring, control valve, O-ring seal and O-ring. 11. Install reservoir or return
tube, then clips if equipped.
CB Series
DISASSEMBLE
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6522
Exploded View Of CB Series Power Steering Pump
1. Remove reservoir retaining clips from reservoir assembly and housing. 2. Separate reservoir
from housing, then remove O-ring from reservoir. 3. Remove O-ring union fitting and O-ring. 4.
Remove control valve assembly and flow control spring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6523
5. Protect drive shaft with shim stock. 6. Using a small chisel, cut drive shaft seal. 7. Remove drive
shaft seal from housing.
8. Insert a small punch through access hole in housing, then remove retaining ring from housing. 9.
Remove pump internal components by gently pushing on drive shaft.
10. Remove O-ring from pump housing. 11. Remove dowel pins, end cover, pressure plate spring
and O-ring from pressure plate. 12. Remove pump ring and vanes from drive shaft subassembly.
13. Remove shaft retaining ring from drive shaft. 14. Remove pump rotor and thrust plate from
drive shaft.
INSPECTION
1. Check the following parts for any scoring, pitting or chatter marks:
a. Pressure plate. b. Pump ring. c. Rotor. d. Vanes. e. Thrust plate. f.
Drive shaft.
2. Replace any parts with any signs of excessive wear or damage.
ASSEMBLE
1. Clean all parts in power steering fluid, then thoroughly dry all parts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6524
2. Lubricate new drive shaft seal with power steering fluid, then install seal into pump housing using
suitable seal installation tool or socket. 3. Install pump ring dowel pins into pump housing. 4. Install
thrust plate, pump rotor and new shaft retaining ring onto drive shaft. 5. Install drive shaft
subassembly into pump housing. 6. Install vanes into pump rotor.
7. Install pump ring onto dowel pins. 8. Lubricate new oil ring with power steering fluid, then install
O-ring into end cover. 9. Lubricate outer edge of end cover with power steering fluid, then press
end cover into pump housing.
10. Insert O-ring into groove in pump housing with ring opening near access hole in pump housing.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Overhaul > Page 6525
Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation
1. Disconnect battery ground cable, then remove serpentine drive belt. 2. Raise and support
vehicle, then place drain pan under vehicle. 3. Disconnect low pressure hose and high pressure
line from pump, then remove hose from pump to remote reservoir. 4. Remove right wheel, then the
bolts holding pump to generator/power steering/belt tensioner mounting bracket. 5. Remove nut
and bolt holding engine block to pump support strut. Remove strut from engine and pump. Lay
pump assembly down on top of
steering gear.
6. Remove serpentine drive belt tensioner from bracket, then generator/pump bracket and support
strut. 7. Lower vehicle, then remove power steering reservoir from vehicle. 8. Remove engine
wiring harness routing clip from generator bracket. 9. Loosen bolt holding engine bracket assembly
to engine support assembly.
10. Remove upper generator to generator bracket mounting bolt, then rotate generator assembly
back toward dash panel. 11. Remove generator bracket from engine and intake manifold. 12.
Remove lower generator mounting bolt. With wiring harness connected, remove generator and
place on intake manifold. 13. Remove power steering pump out through top, in area between
engine and dash panel where generator was mounted. 14. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
DISARMING
1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at
least ten minutes after disconnecting battery ground cable before performing any further repairs on
vehicle. The SRS system is
designed to retain enough voltage to deploy air bag for a short time even after battery has been
disconnected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming > Page 6531
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
ARMING
1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side
of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one
is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning
light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate
SRS system is functioning correctly.
5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air
Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information >
Specifications > Mechanical Specifications
Steering Gear: Mechanical Specifications
Component ..........................................................................................................................................
....................................................... Torque/Ft. Lbs.
High Pressure Hose Tube Nuts ...........................................................................................................
............................................................................... 25 Return Tube Nut .............................................
..............................................................................................................................................................
...... 25 Steering Gear to Subframe Bolts .............................................................................................
........................................................................................... 50 Tie Rod End Locknut ..........................
..............................................................................................................................................................
................. 55 Tie Rod End To Steering Knuckle Attaching Nut
..............................................................................................................................................................
35
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information >
Specifications > Mechanical Specifications > Page 6536
Steering Gear: Pressure, Vacuum and Temperature Specifications
Initial Pressure, psi ..............................................................................................................................
.......................................................................... 50-80 Maximum Pressure, psi ..................................
..............................................................................................................................................................
.. 1300 Relief Pressure, psi .................................................................................................................
.............................................................................. 1200-1300
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information >
Specifications > Page 6537
Steering Gear: Application and ID
Steering Gear ......................................................................................................................................
.................................................. TRW Rack & Pinion
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information >
Specifications > Page 6538
Steering Gear: Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information >
Specifications > Page 6539
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > FWD
Steering Gear: Service and Repair FWD
1. Raise and support vehicle, then remove front wheels. 2. Remove tie rod ends using a suitable
puller. 3. Remove splash shields and boot seal shields, then 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 steering gear from left side of vehicle. 6. Reverse procedure to install,
noting following:
a. For manual gear, make sure master serrations are inline. b. Right rear crossmember bolt is a
pilot bolt that correctly locates 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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > FWD > Page 6542
Steering Gear: Service and Repair AWD
1. Remove steering column as described in Steering Column Replacement. 2. Remove tie rod
ends from steering knuckle using suitable puller.
Fig. 30 Bridge Assembly (AWD)
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > FWD > Page 6543
Fig. 31 Steering Gear Assembly (AWD)
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. 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Recalls: > NHTSA00V305000 > Oct > 00 > Recall 00V305000: Steering Wheel Separation
Steering Wheel: Recalls Recall 00V305000: Steering Wheel Separation
Vehicle Description: Mini vans equipped with 2-spoke luxury wheels manufactured July 1992
through June 1993; or equipped with 4-spoke sport wheels manufactured from July 1992 through
September 1993. The steering wheel armature stamping can crack and separate from the center
hub attachment to the steering column.
If the steering wheel separates from the center hub attachment to the steering column, loss of
control can occur increasing the risk of an accident.
Dealers will inspect the steering wheel for cracks and any wheels with cracks will be replaced. All
other vehicles will have a reinforcement plate installed to prevent steering wheel separation in the
event cracking occurs.
Owner notification began November 6, 2000. Owners who take their vehicles to an authorized
dealer on an agreed upon service date and do not receive the free remedy within a reasonable
time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles
Steering Wheel: Customer Interest Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 6557
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Wheel: > NHTSA00V305000 > Oct > 00 > Recall 00V305000:
Steering Wheel Separation
Steering Wheel: All Technical Service Bulletins Recall 00V305000: Steering Wheel Separation
Vehicle Description: Mini vans equipped with 2-spoke luxury wheels manufactured July 1992
through June 1993; or equipped with 4-spoke sport wheels manufactured from July 1992 through
September 1993. The steering wheel armature stamping can crack and separate from the center
hub attachment to the steering column.
If the steering wheel separates from the center hub attachment to the steering column, loss of
control can occur increasing the risk of an accident.
Dealers will inspect the steering wheel for cracks and any wheels with cracks will be replaced. All
other vehicles will have a reinforcement plate installed to prevent steering wheel separation in the
event cracking occurs.
Owner notification began November 6, 2000. Owners who take their vehicles to an authorized
dealer on an agreed upon service date and do not receive the free remedy within a reasonable
time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles
Steering Wheel: All Technical Service Bulletins Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles > Page 6567
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles
Steering Wheel: All Technical Service Bulletins Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles > Page 6573
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Wheel: > NHTSA00V305000 > Oct > 00 > Recall 00V305000:
Steering Wheel Separation
Steering Wheel: All Technical Service Bulletins Recall 00V305000: Steering Wheel Separation
Vehicle Description: Mini vans equipped with 2-spoke luxury wheels manufactured July 1992
through June 1993; or equipped with 4-spoke sport wheels manufactured from July 1992 through
September 1993. The steering wheel armature stamping can crack and separate from the center
hub attachment to the steering column.
If the steering wheel separates from the center hub attachment to the steering column, loss of
control can occur increasing the risk of an accident.
Dealers will inspect the steering wheel for cracks and any wheels with cracks will be replaced. All
other vehicles will have a reinforcement plate installed to prevent steering wheel separation in the
event cracking occurs.
Owner notification began November 6, 2000. Owners who take their vehicles to an authorized
dealer on an agreed upon service date and do not receive the free remedy within a reasonable
time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 6579
Steering Wheel: Service and Repair
1. Ensure front wheels are straight and steering column is locked, then disconnect battery ground
cable. 2. Remove four air bag module attaching nuts from back of steering wheel, then lift module
and disconnect rear module connector. 3. Remove vehicle speed control switch and connector. 4.
Remove steering wheel retaining nut and pull steering wheel with puller tool No. C-3428B, or
equivalent. 5. Reverse procedure to install. Torque steering wheel attaching nut to 45 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications
Tightening Specifications Part 1 Of 2
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection
Ball Joint: Testing and Inspection
Fig. 9 Ball Joint Wear 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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 6587
Ball Joint: Service and Repair
BALL JOINT REMOVAL
(1) Pry off seal.
(2) Position Receiving Cup Tool C-4699-2 to support lower control arm while receiving ball joint
assembly.
(3) Install 1-1/16 inch deep socket over ball joint stud and against the ball joint upper housing.
(4) Press down against the ball joint upper housing, to remove ball joint assembly from lower
control arm.
BALL JOINT INSTALLATION
(1) By hand, position ball joint assembly into the ball joint bore of the lower control arm. Be sure the
ball joint assembly is not cocked in the bore of
the control arm, this will cause binding of the ball assembly.
(2) Position assembly in press with Installer Tool 1C-4699-1 supporting control arm.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 6588
(3) Install the Receiver Cup, Special Tool C-4699-2 -over the ball joint stud and down on the lower
control arm assembly.
(4) Carefully align all pieces. Using an arbor press apply pressure against the control arm
assembly, until ball joint is fully seated against bottom
surface of control arm. Do not apply excessive pressure against the control arm.
BALL JOINT SEAL INSTALLATION
(1) Support ball joint housing with Installer, Special Tool C-4699-1. Position new seal over ball joint
stud and against ball joint housing.
(2) With 1-1/2 inch socket, press seal onto ball joint housing until it is squarely seated against top
surface of control arm as shown.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service
and Repair
Control Arm: Service and Repair
Fig. 12 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 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 CV 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
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service
and Repair > Page 6592
1. Install retainer, bushing and sleeve on stub strut. 2. Position control arm over sway bar, then
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, then loosely assemble nut. 5. Install ball
joint stud into steering knuckle, then 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 >
Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left
Cross-Member: Customer Interest Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left
NO: 22-07-94
GROUP: Tires and Wheels
DATE: Oct. 21, 1994
SUBJECT: Tire Leads/Drifts Left
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11,
1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE
BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING
1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL
REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift
tendencies.
DIAGNOSIS:
Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to
the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight
drift to the left is expected and normal.
If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following
diagnostic procedures should be followed:
A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected,
return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel
assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is
unchanged, perform step B of the diagnosis.
B. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure.
PARTS REQUIRED:
1 6502553 Screw and Washer Assembly
REPAIR PROCEDURE:
This bulletin involves repositioning the front crossmember.
1. Raise the vehicle on a hoist that leaves the front wheels unsupported.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 >
Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 6601
2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame
structure (Refer to the Illustration).
3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment
position of the front crossmember.
4. Loosen the two front and right rear front crossmember attachments.
5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front
crossmember assembly forward using the right rear attachment as the pivot point for the rotation
(looking at the front crossmember from underneath the vehicle, this will be a counterclockwise
rotation). Rotate the crossmember until it contacts the left rear crossmember fastener.
6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is
held against the left rear fastener.
7. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
**8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-00-01-95 (Includes Alignment) 1.0 Hrs.
FAILURE CODE: **LL - Leads Left**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 >
Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left
Cross-Member: All Technical Service Bulletins Crossmember/Alignment/Wheels/Tires - Vehicle
Drifts Left
NO: 22-07-94
GROUP: Tires and Wheels
DATE: Oct. 21, 1994
SUBJECT: Tire Leads/Drifts Left
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11,
1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE
BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING
1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL
REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift
tendencies.
DIAGNOSIS:
Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to
the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight
drift to the left is expected and normal.
If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following
diagnostic procedures should be followed:
A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected,
return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel
assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is
unchanged, perform step B of the diagnosis.
B. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure.
PARTS REQUIRED:
1 6502553 Screw and Washer Assembly
REPAIR PROCEDURE:
This bulletin involves repositioning the front crossmember.
1. Raise the vehicle on a hoist that leaves the front wheels unsupported.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 >
Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 6607
2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame
structure (Refer to the Illustration).
3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment
position of the front crossmember.
4. Loosen the two front and right rear front crossmember attachments.
5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front
crossmember assembly forward using the right rear attachment as the pivot point for the rotation
(looking at the front crossmember from underneath the vehicle, this will be a counterclockwise
rotation). Rotate the crossmember until it contacts the left rear crossmember fastener.
6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is
held against the left rear fastener.
7. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
**8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-00-01-95 (Includes Alignment) 1.0 Hrs.
FAILURE CODE: **LL - Leads Left**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component
Information > Service and Repair
Ball Stud: Service and Repair
Fig. 18 Steering Knuckle Assembly
REMOVAL
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied.
NOTE:
Hub and driveshaft are splined together through knuckle (bearing) and retained by 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 CV 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
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 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:
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component
Information > Service and Repair > Front
Stabilizer Bar: Service and Repair Front
Fig. 23 Stabilizer Bar Assembly
REMOVAL
1. Raise and support vehicle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component
Information > Service and Repair > Front > Page 6615
2. Remove nuts, bolts and retainers at control arms. 3. Remove crossmember clamp attaching
bolts, then 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 bolts. 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component
Information > Service and Repair > Front > Page 6616
Stabilizer Bar: Service and Repair Rear
REMOVAL
1. Raise and support vehicle.
Fig. 6 Rear Sway Bar Assembly
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps
Strut / Shock Tower: Customer Interest Front Suspension - Rapping Noise On Bumps
NO: 02-19-94
GROUP: Front Suspension
DATE: Nov. 25, 1994
SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**.
MODELS:
1994 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps.
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s).
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion recommendations.
5. Reinstall the strut assembly(s).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps >
Page 6625
6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe
adjustment 0.1 degree toe in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 (One Side) 1.4 Hrs.
02-27-01-95 (Both Sides) 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise
Strut / Shock Tower: Customer Interest Front Coil Spring - Metallic Rapping Noise
NO.: 02-08-93
GROUP: Front Suspension
DATE: Oct. 29, 1993
SUBJECT: Noise Due To Coil Spring To Strut Tower Contact
MODELS:
1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country
NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93
(MDH 0820xx).
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s).
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This repair involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the
1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105)
beginning on page 2-8.
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page
6630
recommendations.
5. Reinstall the strut assembly(s).
6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3
degrees and toe adjustment 0.1 degree tow in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 One Side 1.4 Hrs.
02-27-01-95 Both Sides 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front
Suspension - Rapping Noise On Bumps
Strut / Shock Tower: All Technical Service Bulletins Front Suspension - Rapping Noise On Bumps
NO: 02-19-94
GROUP: Front Suspension
DATE: Nov. 25, 1994
SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**.
MODELS:
1994 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps.
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s).
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion recommendations.
5. Reinstall the strut assembly(s).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front
Suspension - Rapping Noise On Bumps > Page 6636
6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe
adjustment 0.1 degree toe in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 (One Side) 1.4 Hrs.
02-27-01-95 (Both Sides) 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose Squeaking Noise
Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise
NO: 24-02-94
GROUP: Heat & A/C
DATE: Jan. 14, 1994
SUBJECT: Squeak in Right Shock Tower Area
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right
shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in
the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn
through, a squeak may occur under driving conditions. Inspect the hose and bracket area and
relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil
Spring - Metallic Rapping Noise
Strut / Shock Tower: All Technical Service Bulletins Front Coil Spring - Metallic Rapping Noise
NO.: 02-08-93
GROUP: Front Suspension
DATE: Oct. 29, 1993
SUBJECT: Noise Due To Coil Spring To Strut Tower Contact
MODELS:
1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country
NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93
(MDH 0820xx).
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s).
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This repair involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the
1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105)
beginning on page 2-8.
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil
Spring - Metallic Rapping Noise > Page 6645
recommendations.
5. Reinstall the strut assembly(s).
6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3
degrees and toe adjustment 0.1 degree tow in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 One Side 1.4 Hrs.
02-27-01-95 Both Sides 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose Squeaking Noise
Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise
NO: 24-02-94
GROUP: Heat & A/C
DATE: Jan. 14, 1994
SUBJECT: Squeak in Right Shock Tower Area
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right
shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in
the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn
through, a squeak may occur under driving conditions. Inspect the hose and bracket area and
relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 021994 > Nov > 94 >
Front Suspension - Rapping Noise On Bumps
Suspension Spring ( Coil / Leaf ): Customer Interest Front Suspension - Rapping Noise On Bumps
NO: 02-19-94
GROUP: Front Suspension
DATE: Nov. 25, 1994
SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**.
MODELS:
1994 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps.
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s).
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion recommendations.
5. Reinstall the strut assembly(s).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 021994 > Nov > 94 >
Front Suspension - Rapping Noise On Bumps > Page 6659
6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe
adjustment 0.1 degree toe in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 (One Side) 1.4 Hrs.
02-27-01-95 (Both Sides) 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 233094 > Mar > 94 >
Rear Leaf Springs - Floor Pan Ticking Noise
Suspension Spring ( Coil / Leaf ): Customer Interest Rear Leaf Springs - Floor Pan Ticking Noise
NO: 23-30-94 GROUP: Body DATE: Mar. 25, 1994
SUBJECT: Ticking Noise from Under Floor Pan
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A ticking noise can be heard coming from under the floor pan near the area of the bases of the
middle seat(s) while driving, but is more evident during cornering.
DIAGNOSIS:
Ensure the middle seats are properly latched in position. Test drive the vehicle and make cornering
maneuvers or go over expansion strips in the road surface and listen for the sound. Perform the
repair procedure if a ticking noise is heard.
PARTS REQUIRED:
AR 4318035 Mopar Spray Gasket Sealant
REPAIR PROCEDURE:
This bulletin involves applying a film between the floor pan and the front mounting bracket(s) for the
rear leaf spring(s).
1. Raise the vehicle on an appropriate hoist.
2. Loosen and back out (without removing) the bolts securing the front mounting bracket of the leaf
spring.
3. Spray Mopar Spray Gasket Sealant (P/N 4318035) between the mounting surface on the bottom
of the vehicle and the front mounting bracket of the leaf spring.
4. Torque the attaching bolts of the front mounting bracket for the leaf spring to 45 ft. lbs. (115
N-m).
5. Repeat steps 1 through 4 for the opposite side if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 02-30-35-90 0.2 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 020893 > Oct > 93 >
Front Coil Spring - Metallic Rapping Noise
Suspension Spring ( Coil / Leaf ): Customer Interest Front Coil Spring - Metallic Rapping Noise
NO.: 02-08-93
GROUP: Front Suspension
DATE: Oct. 29, 1993
SUBJECT: Noise Due To Coil Spring To Strut Tower Contact
MODELS:
1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country
NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93
(MDH 0820xx).
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s).
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This repair involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the
1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105)
beginning on page 2-8.
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 020893 > Oct > 93 >
Front Coil Spring - Metallic Rapping Noise > Page 6668
recommendations.
5. Reinstall the strut assembly(s).
6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3
degrees and toe adjustment 0.1 degree tow in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 One Side 1.4 Hrs.
02-27-01-95 Both Sides 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 021994 >
Nov > 94 > Front Suspension - Rapping Noise On Bumps
Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Suspension - Rapping Noise
On Bumps
NO: 02-19-94
GROUP: Front Suspension
DATE: Nov. 25, 1994
SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**.
MODELS:
1994 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps.
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s).
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion recommendations.
5. Reinstall the strut assembly(s).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 021994 >
Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 6674
6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe
adjustment 0.1 degree toe in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 (One Side) 1.4 Hrs.
02-27-01-95 (Both Sides) 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 233094 >
Mar > 94 > Rear Leaf Springs - Floor Pan Ticking Noise
Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Rear Leaf Springs - Floor Pan
Ticking Noise
NO: 23-30-94 GROUP: Body DATE: Mar. 25, 1994
SUBJECT: Ticking Noise from Under Floor Pan
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A ticking noise can be heard coming from under the floor pan near the area of the bases of the
middle seat(s) while driving, but is more evident during cornering.
DIAGNOSIS:
Ensure the middle seats are properly latched in position. Test drive the vehicle and make cornering
maneuvers or go over expansion strips in the road surface and listen for the sound. Perform the
repair procedure if a ticking noise is heard.
PARTS REQUIRED:
AR 4318035 Mopar Spray Gasket Sealant
REPAIR PROCEDURE:
This bulletin involves applying a film between the floor pan and the front mounting bracket(s) for the
rear leaf spring(s).
1. Raise the vehicle on an appropriate hoist.
2. Loosen and back out (without removing) the bolts securing the front mounting bracket of the leaf
spring.
3. Spray Mopar Spray Gasket Sealant (P/N 4318035) between the mounting surface on the bottom
of the vehicle and the front mounting bracket of the leaf spring.
4. Torque the attaching bolts of the front mounting bracket for the leaf spring to 45 ft. lbs. (115
N-m).
5. Repeat steps 1 through 4 for the opposite side if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 02-30-35-90 0.2 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 020893 >
Oct > 93 > Front Coil Spring - Metallic Rapping Noise
Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Coil Spring - Metallic
Rapping Noise
NO.: 02-08-93
GROUP: Front Suspension
DATE: Oct. 29, 1993
SUBJECT: Noise Due To Coil Spring To Strut Tower Contact
MODELS:
1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country
NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93
(MDH 0820xx).
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s).
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This repair involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the
1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105)
beginning on page 2-8.
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 020893 >
Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 6683
recommendations.
5. Reinstall the strut assembly(s).
6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3
degrees and toe adjustment 0.1 degree tow in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 One Side 1.4 Hrs.
02-27-01-95 Both Sides 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Coil Spring Replace
Suspension Spring ( Coil / Leaf ): Service and Repair Front Coil Spring Replace
Fig. 11 Strut Damper Mount Assembly
1. Remove strut damper assembly as outlined under Strut Damper Assembly Replacement. 2.
Compress coil spring using suitable tool. 3. Remove strut rod nut while holding strut rod to prevent
rotation. 4. Remove 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Coil Spring Replace > Page 6686
Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement
Fig. 1 Rear Axle & Suspension Assembly (FWD)
FWD models
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Coil Spring Replace > Page 6687
Fig. 2 Rear Axle & Suspension Assembly (RWD)
AWD models
REMOVAL
1. Raise and support vehicle, then position suitable floor jack below axle assembly and raise axle
assembly to relieve weight on rear springs. 2. Disconnect height sensor actuator assembly, then
lower ends of rear shock absorbers at axle brackets. 3. Remove U-bolt attaching nuts and
washers, then U-bolt. 4. Disconnect and lower rear axle assembly, allowing rear spring to hang
free. 5. Remove four attaching bolts from front spring hanger. 6. Remove rear spring shackle
attaching nuts and plate, then shackle from spring. 7. Remove front pivot bolt from front spring
hanger. 8. Remove springs from vehicle.
INSTALLATION
1. Assemble shackle, bushings and plate on rear of spring and rear spring hanger, then install
shackle bolt. Do not tighten nut at this point. 2. Assemble front spring hanger to front of spring eye,
then install pivot bolt. Do not tighten nut at this point. Pivot bolt must face inboard to
prevent structural damage during installation of spring.
3. Raise front spring, then install four hanger attaching bolts. Tighten bolts to specifications, then
connect actuator assembly. 4. Raise axle assembly with axle centered below spring center bolt,
then install U-bolt and washer. Tighten U-bolt attaching nut to specifications. 5. Install shock
absorbers and attaching nuts. Do not tighten nuts at this point. 6. Lower vehicle to floor, allowing
full weight of vehicle on wheels, then tighten following fasteners to specifications: front pivot bolt,
shackle nuts
and shock absorber bolts.
7. Connect rear brake proportioning valve spring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement
Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Replacement
1. Raise and support vehicle. 2. Support axle with a suitable jack stand. 3. Remove lower shock
bolt. 4. While holding shock, remove upper shock bolt. 5. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6692
Suspension Strut / Shock Absorber: Service and Repair Replacement
Fig. 28 Strut Damper Assembly Removal
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6693
Fig. 29 Strut Damper Assembly Installation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Adjustments
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel.
3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay
should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter
pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front
Wheel Bearing: Service and Repair Front
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 6699
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 6700
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 6701
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 6702
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 6703
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 6704
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 6705
Wheel Bearing: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front
Wheel Hub: Service and Repair Front
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front > Page 6710
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front > Page 6711
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front > Page 6712
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front > Page 6713
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front > Page 6714
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front > Page 6715
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Front > Page 6716
Wheel Hub: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Locations
Fig. 1 Caravan, Town & Country & Voyager
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6729
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6730
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6731
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6732
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6733
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6734
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6735
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6736
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6742
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6743
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6744
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6745
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6746
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6747
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6748
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6749
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout
Tires: All Technical Service Bulletins Tire & Wheel - Runout
NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT: Tire & Wheel Runout
MODELS: 1994 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge
measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the
tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the
following specifications and appropriate Service Manual procedures.
PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating
the tire on the wheel (match mounting).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake
Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake
NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994
SUBJECT: Smooth Road Vibration/Shake
MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A smooth road vibration/shake condition may be observed on smooth roads as:
- Low speed lateral wobble of the body (0-30 MPH)
- Steering wheel/seat/floor pan vibration at high speeds (60+ MPH)
Use the following flow chart for diagnosis and correction:
DYNAMIC CHECK
Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and
magnitude of vibration/shake condition.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6758
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6759
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6760
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6761
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6762
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout
Tires: All Technical Service Bulletins Tire & Wheel - Runout
NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT: Tire & Wheel Runout
MODELS: 1994 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge
measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the
tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the
following specifications and appropriate Service Manual procedures.
PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating
the tire on the wheel (match mounting).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake
Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake
NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994
SUBJECT: Smooth Road Vibration/Shake
MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A smooth road vibration/shake condition may be observed on smooth roads as:
- Low speed lateral wobble of the body (0-30 MPH)
- Steering wheel/seat/floor pan vibration at high speeds (60+ MPH)
Use the following flow chart for diagnosis and correction:
DYNAMIC CHECK
Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and
magnitude of vibration/shake condition.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6772
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6773
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6774
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6775
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6776
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels
Wheels: Recalls Recall - Stamped Steel Road Wheels
No. 603
January, 1994
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Safety Recall # 603 -- Stamped Steel Road Wheels
Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town
and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel
Wheels and/or a 15" Full Size Stamped Steel Spare.
The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut
torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing
plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this
recall.
IMPORTANT:
Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete
this recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the
same street address) will receive a copy of this dealer recall notification letter and a list of the
involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible
dealership personnel should be instructed to sign for this Certified Mail without hesitation as it
concerns urgent safety recall information.
The Vehicle List is 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.
All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall
notification letter by Compak mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall
implementation for dealer inquiry by VIN as needed.
Parts
Important:
Due to the small number of involved vehicles and the unknown number of wheels required for each
vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to
support scheduled repairs.
Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer
demand. Owners were requested to inspect their vehicle to determine the number of replacement
wheels required. Dealers should inquire if the owner performed the inspection and order the
required parts when scheduling the service appointment.
Each parts package contains the components (see illustration).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6785
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 inspect wheels for the suspect manufacturing plant code and/or
schedule appointments for the service with their dealers at the earliest possible date. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Service Procedure
A. Inspect Wheel Manufacturing Plant Code:
NOTE:
Vehicle may have one, four or five wheels to be inspected.
A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF):
a. Remove all wheel covers.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB):
a. Gain access to spare.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6786
A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected
wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel
covers and/or secure spare, no further action is required.
NOTE:
Replace only those wheels having the M1 plant code.
B. Replace Wheel:
B1. Remove all wheels with suspect M1 plant code. Discard lug nuts.
B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center.
B3. Install supplied valve stem(s).
B4. Mount and balance tire(s) on supplied wheel(s).
B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs.
(130 N-m) torque.
B6. Reinstall wheel cover(s) and/or secure spare.
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 labor operation numbers and time allowances (see illustration).
Add the cost of any recall parts packages used plus applicable dealer allowance to your claim.
Parts Return
Removed wheels must be returned to the Warranty Material Return Center.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim
processing and material return instructions.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6787
SAFETY RECALL -- Stamped Steel Road Wheels
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in
some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager
vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel
becoming loose. This could result in an accident without prior warning.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange
for service to correct the condition without delay. The service and required parts as described in
this letter will be provided free of charge.
The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper,
which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with
15" wheels with full wheel covers and also for 15" full size spare tires.
You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of
this letter for details. If no suspect wheels are found, no further action is necessary. Please mark
"INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner
notification form and put it in the mail. No postage is required. If you prefer not to do the inspection
yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect
the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection
will take less than one-half hour to complete. However, additional time may be required depending
on how many wheels require replacement and how dealer appointments are scheduled and
processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the service. If you
performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels
found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service
appointment.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it
to your dealer. The form identifies the vehicle and the service that is required.
If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll
free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired.
We regret any inconvenience which this action may cause you. However, we are concerned about
your safety. If your dealer fails or is unable to remedy this defect without charge and within a
reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free
Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.
STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN,
PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY
FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^
Remove all wheel covers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6788
^ Inspect wheel manufacturing plant code located above valve stem as shown.
^ Reinstall wheel covers.
FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain
access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing
plant code located above valve stem as shown.
If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment
with your dealer to have the suspect wheel(s) replaced.
NOTE:
Plant code may be covered by a green sticker. Remove and discard sticker as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6794
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6795
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6796
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6797
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6798
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6799
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6800
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 6801
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6807
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6808
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6809
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6810
WHEEL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6811
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6812
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6813
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6814
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout
Wheels: All Technical Service Bulletins Tire & Wheel - Runout
NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT: Tire & Wheel Runout
MODELS: 1994 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge
measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the
tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the
following specifications and appropriate Service Manual procedures.
PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating
the tire on the wheel (match mounting).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake
Wheels: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake
NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994
SUBJECT: Smooth Road Vibration/Shake
MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A smooth road vibration/shake condition may be observed on smooth roads as:
- Low speed lateral wobble of the body (0-30 MPH)
- Steering wheel/seat/floor pan vibration at high speeds (60+ MPH)
Use the following flow chart for diagnosis and correction:
DYNAMIC CHECK
Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and
magnitude of vibration/shake condition.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6823
VISUAL INSPECTION (See illustration)
TIRE/WHEEL/HUB RUNOUT CHECKS
NOTE:
ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6824
Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1).
Mark the point of maximum radial and lateral runout on the tires/wheels.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6825
Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check
the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel
mounted on an off car balancer.
SPECIFICATIONS: Radial runout:
0.030 in. (0.762 mm) or LESS
Lateral runout: 0.030 in. (0.762 mm) or LESS
NOTE:
HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD)
VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6826
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road
Vibration/Shake > Page 6827
Measure hub wheel pilot diameter (refer to Figure 4).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels
Wheels: All Technical Service Bulletins Recall - Stamped Steel Road Wheels
No. 603
January, 1994
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Safety Recall # 603 -- Stamped Steel Road Wheels
Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town
and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel
Wheels and/or a 15" Full Size Stamped Steel Spare.
The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut
torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing
plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this
recall.
IMPORTANT:
Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete
this recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the
same street address) will receive a copy of this dealer recall notification letter and a list of the
involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible
dealership personnel should be instructed to sign for this Certified Mail without hesitation as it
concerns urgent safety recall information.
The Vehicle List is 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.
All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall
notification letter by Compak mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall
implementation for dealer inquiry by VIN as needed.
Parts
Important:
Due to the small number of involved vehicles and the unknown number of wheels required for each
vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to
support scheduled repairs.
Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer
demand. Owners were requested to inspect their vehicle to determine the number of replacement
wheels required. Dealers should inquire if the owner performed the inspection and order the
required parts when scheduling the service appointment.
Each parts package contains the components (see illustration).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels >
Page 6832
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 inspect wheels for the suspect manufacturing plant code and/or
schedule appointments for the service with their dealers at the earliest possible date. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Service Procedure
A. Inspect Wheel Manufacturing Plant Code:
NOTE:
Vehicle may have one, four or five wheels to be inspected.
A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF):
a. Remove all wheel covers.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB):
a. Gain access to spare.
b. Inspect wheel manufacturing plant code located above valve stem (Figure 1).
NOTE:
Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as
necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels >
Page 6833
A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected
wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel
covers and/or secure spare, no further action is required.
NOTE:
Replace only those wheels having the M1 plant code.
B. Replace Wheel:
B1. Remove all wheels with suspect M1 plant code. Discard lug nuts.
B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center.
B3. Install supplied valve stem(s).
B4. Mount and balance tire(s) on supplied wheel(s).
B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs.
(130 N-m) torque.
B6. Reinstall wheel cover(s) and/or secure spare.
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 labor operation numbers and time allowances (see illustration).
Add the cost of any recall parts packages used plus applicable dealer allowance to your claim.
Parts Return
Removed wheels must be returned to the Warranty Material Return Center.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim
processing and material return instructions.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels >
Page 6834
SAFETY RECALL -- Stamped Steel Road Wheels
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in
some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager
vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel
becoming loose. This could result in an accident without prior warning.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange
for service to correct the condition without delay. The service and required parts as described in
this letter will be provided free of charge.
The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper,
which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with
15" wheels with full wheel covers and also for 15" full size spare tires.
You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of
this letter for details. If no suspect wheels are found, no further action is necessary. Please mark
"INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner
notification form and put it in the mail. No postage is required. If you prefer not to do the inspection
yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect
the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection
will take less than one-half hour to complete. However, additional time may be required depending
on how many wheels require replacement and how dealer appointments are scheduled and
processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the service. If you
performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels
found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service
appointment.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it
to your dealer. The form identifies the vehicle and the service that is required.
If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll
free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired.
We regret any inconvenience which this action may cause you. However, we are concerned about
your safety. If your dealer fails or is unable to remedy this defect without charge and within a
reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free
Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.
STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN,
PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY
FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^
Remove all wheel covers.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels >
Page 6835
^ Inspect wheel manufacturing plant code located above valve stem as shown.
^ Reinstall wheel covers.
FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain
access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing
plant code located above valve stem as shown.
If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment
with your dealer to have the suspect wheel(s) replaced.
NOTE:
Plant code may be covered by a green sticker. Remove and discard sticker as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting
Shifter M/T: All Technical Service Bulletins M/T - Shifter Squeak When Shifting
NO: 21-09-94
GROUP: Transmission
EFFECTIVE DATE: Jun. 10 1994
SUBJECT: Shifter Squeak - Manual Transmission
MODELS:
1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1994 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION.
DISCUSSION:
A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the
select shift cable attaches to the gear shift lever.
DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE.
PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE
ISOLATOR.
If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined
in the appropriate service manual. The correct part numbers for the shifter assembly are listed
below:
4670218 AP and AA Vehicles
4670219 AS Vehicles
4670220 PL Vehicles
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Adjustments
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel.
3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay
should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter
pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front
Wheel Bearing: Service and Repair Front
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 6851
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 6852
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 6853
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 6854
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 6855
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 6856
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 6857
Wheel Bearing: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front
Wheel Hub: Service and Repair Front
This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager
and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering
knuckle by four mounting screws that are removed from the rear of the knuckle assembly.
Remove
1. Remove cotter pin, nut lock, and spring washer.
2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft
are splined together through the knuckle (bearing)
and retained by the hub nut.
3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front > Page 6862
5. Disconnect tie rod end from steering arm with Tool C-3894-A.
6. Remove clamp bolt securing ball joint stud into steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front > Page 6863
7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT
CALIPER WITH WIRE HOOK AND NOT BY
HYDRAULIC HOSE. Remove braking disc.
8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from
driveshaft.
NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft must be supported.
9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front > Page 6864
10. Remove hub and bearing assembly. Replacement of the grease seal is recommended
whenever this service is performed.
Installation
1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65
Nm.).
CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign
material or nicks.
2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle
and dual purpose drive head for installing seal into
knuckle and (head reversed) for installing wear sleeve into C/V joint housing).
3. Assemble tool and install seal.
CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and relubricate BOTH components.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front > Page 6865
4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose
Lubricant or equivalent.
5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball
joint stud.
6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front > Page 6866
7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key.
8. Install braking disc.
9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. Install guide pins and
tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the
threads.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front > Page 6867
10. Install washer and hub nut after cleaning foreign matter from threads.
11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm).
12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut
lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Front > Page 6868
Wheel Hub: Service and Repair Rear
REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease
cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing.
3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard
grease seal, a new seal should be used when reinstalling the inner bearing.
4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity.
To clean bearings, soak them in an appropriate
cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several
times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old
particles of hardened grease from bearings. Repeat this operation until bearings are clean.
Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the
bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing
while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If
bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as
a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings using appropriate solvent and dry bearings.
Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or
equivalent, and place them in a clean covered container until ready for installation. If a bearing
packer is not available, hand pack grease into all cavities between bearing cage and rollers.
5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or
suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in
grease coated hub and bearing cup, and install new grease seals using the appropriate seal
installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly,
inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces.
10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully
slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the
threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the
wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum
assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting
nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in
line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the
wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall
wheel covers if
so equipped.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Recalls: > NHTSA93V215000 > Dec > 93 > Recall 93V215000: Defective Wheel Lug Nut
Seats
Wheel Fastener: Recalls Recall 93V215000: Defective Wheel Lug Nut Seats
WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES.
THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL
SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL
LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO
WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT.
INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE
PROBLEM AND INSTALL NEW LUG NUTS.
SYSTEM: WHEELS; LUGS; NUTS.
VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15"
STAMPED STEEL SPARE WHEEL.
NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT
THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE
ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE
FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY
TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN
1994 PLYMOUTH TRUCK GRAND VOYAGER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > NHTSA93V215000 > Dec > 93 > Recall 93V215000:
Defective Wheel Lug Nut Seats
Wheel Fastener: All Technical Service Bulletins Recall 93V215000: Defective Wheel Lug Nut Seats
WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES.
THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL
SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL
LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO
WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT.
INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE
PROBLEM AND INSTALL NEW LUG NUTS.
SYSTEM: WHEELS; LUGS; NUTS.
VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15"
STAMPED STEEL SPARE WHEEL.
NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT
THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE
ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE
FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY
TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN
1994 PLYMOUTH TRUCK GRAND VOYAGER
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 180594 > Apr > 94 > TCC - Acceleration
Shudder/DTC 38 Set
Torque Converter: All Technical Service Bulletins TCC - Acceleration Shudder/DTC 38 Set
NO: 18-05-94
GROUP: Vehicle Performance
DATE: Apr. 8, 1994
SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation
MODELS:
1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan
1993 (AC) Dynasty/New Yorker/New Yorker Salon
1993 (AG) Daytona
1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1993 - 1994 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92)
1993 - 1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated
Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades
(depending on final drive ratio, approximately 28 to 42 MPH).
This shudder condition is generally the result of leakage in the transmission front pump caused by
a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code
38 (Torque Converter Control Out of Range).
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with 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. If Diagnostic Trouble Code 38 is present, proceed to the
repair procedure. If no codes are present and all systems are functioning correctly, proceed with
the following:
A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as
necessary.
B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any
abnormal conditions that could contribute to low frequency vibrations.
C. Road test the vehicle at normal operating temperatures while monitoring transmission
performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic
section, to display converter clutch function and throttle angle. EMCC shudder generally is
encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on
final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the
shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged.
This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal,
or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair
procedure.
PARTS REQUIRED:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 180594 > Apr > 94 > TCC - Acceleration
Shudder/DTC 38 Set > Page 6887
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.
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 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. Before performing the torque converter clutch break in reset procedure verify that the repair has
corrected the shudder condition. Drive the vehicle under the same conditions that caused the
shudder. If the condition is corrected, go to step four.
NOTE:
SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN
PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and
re-evaluate the items listed.
4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure
listed in the appropriate Service Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS &
1992 - 1993 AY 6.1 Hrs.
1993 - 1994 LH 7.1 Hrs.
21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 180594 > Apr > 94 > TCC - Acceleration
Shudder/DTC 38 Set > Page 6893
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.
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 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. Before performing the torque converter clutch break in reset procedure verify that the repair has
corrected the shudder condition. Drive the vehicle under the same conditions that caused the
shudder. If the condition is corrected, go to step four.
NOTE:
SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN
PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and
re-evaluate the items listed.
4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure
listed in the appropriate Service Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS &
1992 - 1993 AY 6.1 Hrs.
1993 - 1994 LH 7.1 Hrs.
21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Page 6894
Wheel Fastener: Specifications
Fig 6 Wheel Stud Tightening Sequence
When tightening wheel stud nuts, a criss-cross tightening sequence as shown should be followed.
Tighten all stud nuts to one-half specified torque. Repeat, fully tightening to specified torque.
Wheel stud lug nut torque 129 Nm (95 ft lb)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations
Air Conditioning Switch: Locations
Heater A/C Controls
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 240394 > Jan > 94 > Heater - Poor
Performance
Air Door Cable: Customer Interest Heater - Poor Performance
NO: 24-03-94
GROUP: Heating and A/C
DATE: Jan. 28, 1994
SUBJECT: Poor Heater Performance
MODELS:
1992-1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Customer complains of poor heater performance which may be the result of a misadjusted clip on
the blend air door cable. The vehicle will exhibit low air temperature in the full heat position.
DIAGNOSIS:
Move the temperature control lever all the way to the right to the full heat position. If the
temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform
the following repair procedure.
REPAIR PROCEDURE:
This bulletin involves the adjustment of the clip on the blend air door cable.
1. Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start
by opening the ash tray and pulling at one of the bottom corners of the bezel. The bezel is held in
place by a clip at each corner.
2. Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5
mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear
of the A/C control assembly is visible.
3. Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever.
4. Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to
the full cool position.
5. Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to
1/4 in. (3 to 6 mm) farther to the right.
6. Re-install the blend air door cable eyelet over the upstanding tang of the temperature control
lever.
7. Move the temperature control lever to the full heat position. If the control lever has at least .080
in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the
lever still has less than .080 in. (2 mm) of spring back, repeat steps 3 through 7 until spring back is
.080 in. or more.
8. Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs.
(1.9 N-m).
9. Move the temperature control lever to the full cool position and then back to the full heat position.
The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever
springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed
to the full heat position to properly position the clip.
10. Re-install the center bezel being sure that all 4 clips are properly engaged.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
24-50-25-91 0.2 Hrs.
FAILURE CODE: 50 - Improper Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 240394 > Jan > 94 > Heater
- Poor Performance
Air Door Cable: All Technical Service Bulletins Heater - Poor Performance
NO: 24-03-94
GROUP: Heating and A/C
DATE: Jan. 28, 1994
SUBJECT: Poor Heater Performance
MODELS:
1992-1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Customer complains of poor heater performance which may be the result of a misadjusted clip on
the blend air door cable. The vehicle will exhibit low air temperature in the full heat position.
DIAGNOSIS:
Move the temperature control lever all the way to the right to the full heat position. If the
temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform
the following repair procedure.
REPAIR PROCEDURE:
This bulletin involves the adjustment of the clip on the blend air door cable.
1. Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start
by opening the ash tray and pulling at one of the bottom corners of the bezel. The bezel is held in
place by a clip at each corner.
2. Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5
mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear
of the A/C control assembly is visible.
3. Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever.
4. Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to
the full cool position.
5. Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to
1/4 in. (3 to 6 mm) farther to the right.
6. Re-install the blend air door cable eyelet over the upstanding tang of the temperature control
lever.
7. Move the temperature control lever to the full heat position. If the control lever has at least .080
in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the
lever still has less than .080 in. (2 mm) of spring back, repeat steps 3 through 7 until spring back is
.080 in. or more.
8. Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs.
(1.9 N-m).
9. Move the temperature control lever to the full cool position and then back to the full heat position.
The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever
springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed
to the full heat position to properly position the clip.
10. Re-install the center bezel being sure that all 4 clips are properly engaged.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
24-50-25-91 0.2 Hrs.
FAILURE CODE: 50 - Improper Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Technical Service Bulletins > Page 6913
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Technical Service Bulletins > Page 6914
Air Door Cable: Service and Repair
REMOVAL AND INSTALLATION
Temperature Control Cable
1. Disconnect battery negative cable. 2. Remove left silencer (kick pad) panel. 3. Remove parking
brake release handle linkage. 4. Remove lower steering column cover. 5. Remove upper column
cover. 6. Remove upper instrument panel pad. 7. Remove instrument panel upper fence screws. 8.
Remove center instrument panel bezel. 9. Remove heater control unit.
10. Remove vacuum lines at heater control unit. 11. Remove console/module cover. 12. Remove
right silencer (kick pad) panel. 13. Remove left lower reinforcement. 14. Remove lower steering
column shroud. 15. Remove upper column shroud. 16. Disconnect column wiring. 17. Disconnect
shift indicator. 18. Lower steering column. 19. Remove floor braces. 20. Remove right sill plate. 21.
Remove left sill plate. 22. Remove A-pillar intermediate molding. 23. Remove hood release handle.
24. Remove steering column support nuts. 25. Loosen bolts holding instrument panel to cowl side
panels. 26. Roll instrument panel down. 27. Remove temperature control cable.
To install, reverse the preceding operation.
To adjust temperature cable: Position the TEMP lever on the control to the cool side of its travel.
Allowing the self-adjusting clip to slide on the cable, rotate the blend-air door crank
counterclockwise by hand until it stops.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair
Air Duct: Customer Interest Low Heater Performance - Diagnosis/Repair
NO: 24-05-94 Rev. A
GROUP: Heater & A/C
DATE: Dec. 23, 1994
SUBJECT: Low Heater Performance Diagnosis/Repair
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-05-94, DATED MAR. 11,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES
VEHICLES, AND ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
**1992 - 1995 (ES) Chrysler Voyager**
SYMPTOM/CONDITION:
Poor heater system performance at low ambient temperatures consisting of one or more of the
following symptoms:
A) Heater discharge duct temperature drops off at engine idle speed.
B) Poor heater system performance resulting in cooler than expected average cabin temperature.
C) Driver's side floor cold due to lack of direct heater air flow (1993 or 1994 models).
Low heater performance may be caused by many factors within the heater and A/C system, the
engine cooling system and/or the engine electronic management system. Proper diagnosis is
essential to avoid additional customer inconvenience and needless component changes. It is very
important for the Service Advisor/Technician to FIRST determine the specific customer complaint,
and then match it to the three descriptions listed above.
DIAGNOSIS/REPAIR PROCEDURE:
If the customer complaint is SYMPTOM A or SYMPTOM B, perform the heater output test first. If
the customer complaint is SYMPTOM C, go directly to the SYMPTOM C repair procedure.
HEATER OUTPUT TEST
With the engine idling at normal operating temperature, set the temperature control lever to the
maximum heat position, the mode button to the floor position, and the blower switch to high. Using
a thermometer, check the air temperature coming from the center floor outlets (Refer to the
Temperature Reference Chart).
If the vehicle meets the minimum floor outlet temperature specification, the vehicle is performing as
designed and no further action should be taken. If the vehicle does not meet the minimum floor
outlet temperature specification, continue to the appropriate
Diagnosis/Repair Procedure.
SYMPTOM A - Heater discharge duct temperature drops off at idle engine speeds.
NOTE:
A DROP IN OUTLET AIR TEMPERATURE AT IDLE IS NORMAL. THE FOLLOWING STEPS ARE
TO ENSURE THE OUTLET TEMPERATURE IS AS HIGH AS POSSIBLE.
1. Verify with the Mopar Diagnostic System (MDS) Scan Tool (DRB II/III) that the engine idle is
within specification.
Specifications for vehicles with 1000 miles or more: 2.5L 800 - 1200 RPM 3.0L 610 - 900 RPM 3.3L
575 - 875 RPM 3.8L 575 - 875 RPM
2. Verify engine coolant temperature.
A) Does engine temperature gauge read low?
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page
6923
B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating
characteristics. Add 50/50 coolant/water mix if needed.
C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine
systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long)
is present, replace the engine coolant thermostat. If other DTC's are present, record them on the
repair order for future reference and repair as necessary.
SYMPTOM B - Poor heater system performance resulting in cooler than expected average cabin
temperature.
1. Move the temperature control lever all the way to the right to the full heat position. If the
temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform
the following repair procedure.
A) Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start
by opening the ash tray on 1994 models or the glove box door on 1991-1993 models and pulling at
one of the corners of the bezel. The bezel is held in place by a clip at each corner.
B) Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5
mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear
of the A/C control assembly is visible.
C) Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever.
NOTE:
ON 1991-1993 VEHICLES, IT IS NOT NECESSARY TO DISCONNECT THE BLEND AIR CABLE
FROM THE TEMPERATURE CONTROL LEVER.
D) Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to
the full cool position.
E) Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to
1/4 in. (3 to 6 mm) farther to the right.
F) Re-install the blend air door cable eyelet over the upstanding tang of the temperature control
lever.
G) Move the temperature control lever to the full heat position. If the control lever has at least .080
in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the
lever still has less than .080 in. (2 mm) of spring back, repeat steps "c" through "g" until spring back
is .080 in. or more.
H) Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs.
(1.9 N-m).
I) Move the temperature control lever to the full cool position and then back to the full heat position.
The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever
springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed
to the full heat position to properly position the clip.
J) Re-install the center bezel being sure that all 4 clips are properly engaged.
2. Verify engine coolant temperature.
A) Does engine temperature gauge read low?
B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating
characteristics. Add 50/50 coolant/water mix if needed.
C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III) verify that all engine
systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long)
is present, replace the engine coolant thermostat. If other DTC's are present, record them on the
repair order for future reference, and repair as necessary.
3. CAUTION:
Check for hot heater hoses into and out of BOTH the water valve and heater core. Should either
component exhibit a cool temperature at the outlet, that component may be blocked or restricted. If
a heater core is suspect, it should be replaced with an approved MOPAR replacement ONLY!
SYMPTOM C - Drivers side floor cold, due to lack of direct heater air flow.
PARTS REQUIRED:
1 3849219 Duct, Heat Distribution (for use on 1993 model vehicles only)
1993 Model Vehicle Repair Procedure:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page
6924
If the vehicle is not equipped with a lower console, skip to step "i".
A) Remove the center instrument panel bezel by carefully unsnapping it.
B) Remove the two 5/16 in. hex head screws just above the cubby hole.
C) Remove the ash receiver/cupholder assembly by depressing the two latching tabs.
D) Remove the two 5/16 in. hex head screws at the rear of the ash receiver/cupholder assembly
cavity.
E) Remove the two 5/16 in. hex head screws at the lower right and left sides of the console.
F) Pull the console loose and remove the three Phillips head screws holding the cubby hole to the
console assembly. Two are in the front, one is on the rear.
G) Remove the ash tray light.
H) Remove the console.
I) Remove the three 5/16 in. hex head screws holding the floor air distribution duct to the bottom of
the heater/air conditioning housing. Remove the duct and discard it.
J) Install revised duct (P/N 3849219) by reversing the steps above.
1994 Model Vehicle Repair Procedure:
A) If so equipped, remove the two screws at the top and the two screws at the bottom of the
premium console. Remove the console.
B) Remove the three screws attaching the center floor air duct to the main floor air distribution duct.
Remove the center floor air duct.
C) Disconnect the two 25-way connectors from the body control module.
D) Remove the three screws attaching the main floor duct to the climate control unit. Remove the
main floor air duct.
E) Modify the main floor air duct by cutting and taping as shown in the illustration.
F) Reinstall by reversing steps "a" through "d".
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
SYMPTOM A Refer to the appropriate Labor Operation Time Schedule Manual for already existing
Labor Operation No. as necessary.
SYMPTOM B
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page
6925
Labor Operation No. 24-50-25-91
0.2 Hrs.
SYMPTOM C Labor Operation No. 24-65-49-90
1993 model vehicles 0.3 Hrs.
1994 model vehicles 0.5 Hrs.
FAILURE CODE:
SYMPTOM A Refer to the appropriate Labor Operation Time Schedules Manual for already
existing Failure Code as necessary.
SYMPTOM B 50 - Improper Adjustment
SYMPTOM C 1993 model vehicles
P8 - New Part
1994 model vehicles XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > Customer Interest for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors
Air Duct: Customer Interest AC Ducts - Emit Odors
NO.: 24-21-93
GROUP: Air Conditioning
DATE: Sep. 3, 1993
SUBJECT: Air Conditioning Ducts Emits Odor
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS**
MODELS: 1992**- 1993**
(AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX)
1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX)
SYMPTOM/CONDITION:
Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when
the A/C system is first turned on.
Two causes for A/C related odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES
**On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally
results in an excessive amount of corrosion protection coating being applied on the evaporator
external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when
dry fins become wet from condensation.
To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the
appropriate service manual for the replacement procedure.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended
use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more
likely to occur in vehicles that have been in extended use in humid climates. To correct this
condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair
procedure outlined in this bulletin.
PARTS AND EQUIPMENT REQUIRED:
VEHICLES WITH LESS THAN 12,000 MILES
1 Coil, A/C Evaporator
AS 1992 4723069
AS 1993 - 1994 4474842
AC & AY 4677011
VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
1 A/C Evaporator Cleaner 4728942
1 Reusable Applicator 4740319
1 Pair Of Rubber Gloves
1 Pair Of Safety Glasses
REPAIR PROCEDURE:
This bulletin involves cleaning and disinfecting the A/C evaporator and housing.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > Customer Interest for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 6930
- WEAR SAFETY GLASSES AND GLOVES
- AVOID BREATHING VAPORS
- USE WATER TO FLUSH EYES IF NECESSARY
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if
necessary.
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open
all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the
evaporator coil.
4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block.
**NOTE:
THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL
LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING
THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.**
5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at
least 80 PSI of pressure, to the reusable applicator.
6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
7. Turn the vehicle OFF and allow to soak for at least 30 minutes.
8. Wipe off any excess cleaner from around the instrument panel ducts.
9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF,
open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for
20 minutes to dry the system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
Replace Evaporator AC & AY 1992 - 1993
24-65-90-91 2.0 Hrs.
AS 1992 - 1994 24-65-90-91 2.4 Hrs.
Clean Evaporator AC, AS & AY 24-65-90-90
0.3 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair
Air Duct: All Technical Service Bulletins Low Heater Performance - Diagnosis/Repair
NO: 24-05-94 Rev. A
GROUP: Heater & A/C
DATE: Dec. 23, 1994
SUBJECT: Low Heater Performance Diagnosis/Repair
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-05-94, DATED MAR. 11,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES
VEHICLES, AND ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
**1992 - 1995 (ES) Chrysler Voyager**
SYMPTOM/CONDITION:
Poor heater system performance at low ambient temperatures consisting of one or more of the
following symptoms:
A) Heater discharge duct temperature drops off at engine idle speed.
B) Poor heater system performance resulting in cooler than expected average cabin temperature.
C) Driver's side floor cold due to lack of direct heater air flow (1993 or 1994 models).
Low heater performance may be caused by many factors within the heater and A/C system, the
engine cooling system and/or the engine electronic management system. Proper diagnosis is
essential to avoid additional customer inconvenience and needless component changes. It is very
important for the Service Advisor/Technician to FIRST determine the specific customer complaint,
and then match it to the three descriptions listed above.
DIAGNOSIS/REPAIR PROCEDURE:
If the customer complaint is SYMPTOM A or SYMPTOM B, perform the heater output test first. If
the customer complaint is SYMPTOM C, go directly to the SYMPTOM C repair procedure.
HEATER OUTPUT TEST
With the engine idling at normal operating temperature, set the temperature control lever to the
maximum heat position, the mode button to the floor position, and the blower switch to high. Using
a thermometer, check the air temperature coming from the center floor outlets (Refer to the
Temperature Reference Chart).
If the vehicle meets the minimum floor outlet temperature specification, the vehicle is performing as
designed and no further action should be taken. If the vehicle does not meet the minimum floor
outlet temperature specification, continue to the appropriate
Diagnosis/Repair Procedure.
SYMPTOM A - Heater discharge duct temperature drops off at idle engine speeds.
NOTE:
A DROP IN OUTLET AIR TEMPERATURE AT IDLE IS NORMAL. THE FOLLOWING STEPS ARE
TO ENSURE THE OUTLET TEMPERATURE IS AS HIGH AS POSSIBLE.
1. Verify with the Mopar Diagnostic System (MDS) Scan Tool (DRB II/III) that the engine idle is
within specification.
Specifications for vehicles with 1000 miles or more: 2.5L 800 - 1200 RPM 3.0L 610 - 900 RPM 3.3L
575 - 875 RPM 3.8L 575 - 875 RPM
2. Verify engine coolant temperature.
A) Does engine temperature gauge read low?
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair
> Page 6936
B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating
characteristics. Add 50/50 coolant/water mix if needed.
C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine
systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long)
is present, replace the engine coolant thermostat. If other DTC's are present, record them on the
repair order for future reference and repair as necessary.
SYMPTOM B - Poor heater system performance resulting in cooler than expected average cabin
temperature.
1. Move the temperature control lever all the way to the right to the full heat position. If the
temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform
the following repair procedure.
A) Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start
by opening the ash tray on 1994 models or the glove box door on 1991-1993 models and pulling at
one of the corners of the bezel. The bezel is held in place by a clip at each corner.
B) Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5
mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear
of the A/C control assembly is visible.
C) Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever.
NOTE:
ON 1991-1993 VEHICLES, IT IS NOT NECESSARY TO DISCONNECT THE BLEND AIR CABLE
FROM THE TEMPERATURE CONTROL LEVER.
D) Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to
the full cool position.
E) Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to
1/4 in. (3 to 6 mm) farther to the right.
F) Re-install the blend air door cable eyelet over the upstanding tang of the temperature control
lever.
G) Move the temperature control lever to the full heat position. If the control lever has at least .080
in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the
lever still has less than .080 in. (2 mm) of spring back, repeat steps "c" through "g" until spring back
is .080 in. or more.
H) Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs.
(1.9 N-m).
I) Move the temperature control lever to the full cool position and then back to the full heat position.
The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever
springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed
to the full heat position to properly position the clip.
J) Re-install the center bezel being sure that all 4 clips are properly engaged.
2. Verify engine coolant temperature.
A) Does engine temperature gauge read low?
B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating
characteristics. Add 50/50 coolant/water mix if needed.
C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III) verify that all engine
systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long)
is present, replace the engine coolant thermostat. If other DTC's are present, record them on the
repair order for future reference, and repair as necessary.
3. CAUTION:
Check for hot heater hoses into and out of BOTH the water valve and heater core. Should either
component exhibit a cool temperature at the outlet, that component may be blocked or restricted. If
a heater core is suspect, it should be replaced with an approved MOPAR replacement ONLY!
SYMPTOM C - Drivers side floor cold, due to lack of direct heater air flow.
PARTS REQUIRED:
1 3849219 Duct, Heat Distribution (for use on 1993 model vehicles only)
1993 Model Vehicle Repair Procedure:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair
> Page 6937
If the vehicle is not equipped with a lower console, skip to step "i".
A) Remove the center instrument panel bezel by carefully unsnapping it.
B) Remove the two 5/16 in. hex head screws just above the cubby hole.
C) Remove the ash receiver/cupholder assembly by depressing the two latching tabs.
D) Remove the two 5/16 in. hex head screws at the rear of the ash receiver/cupholder assembly
cavity.
E) Remove the two 5/16 in. hex head screws at the lower right and left sides of the console.
F) Pull the console loose and remove the three Phillips head screws holding the cubby hole to the
console assembly. Two are in the front, one is on the rear.
G) Remove the ash tray light.
H) Remove the console.
I) Remove the three 5/16 in. hex head screws holding the floor air distribution duct to the bottom of
the heater/air conditioning housing. Remove the duct and discard it.
J) Install revised duct (P/N 3849219) by reversing the steps above.
1994 Model Vehicle Repair Procedure:
A) If so equipped, remove the two screws at the top and the two screws at the bottom of the
premium console. Remove the console.
B) Remove the three screws attaching the center floor air duct to the main floor air distribution duct.
Remove the center floor air duct.
C) Disconnect the two 25-way connectors from the body control module.
D) Remove the three screws attaching the main floor duct to the climate control unit. Remove the
main floor air duct.
E) Modify the main floor air duct by cutting and taping as shown in the illustration.
F) Reinstall by reversing steps "a" through "d".
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
SYMPTOM A Refer to the appropriate Labor Operation Time Schedule Manual for already existing
Labor Operation No. as necessary.
SYMPTOM B
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair
> Page 6938
Labor Operation No. 24-50-25-91
0.2 Hrs.
SYMPTOM C Labor Operation No. 24-65-49-90
1993 model vehicles 0.3 Hrs.
1994 model vehicles 0.5 Hrs.
FAILURE CODE:
SYMPTOM A Refer to the appropriate Labor Operation Time Schedules Manual for already
existing Failure Code as necessary.
SYMPTOM B 50 - Improper Adjustment
SYMPTOM C 1993 model vehicles
P8 - New Part
1994 model vehicles XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors
Air Duct: All Technical Service Bulletins AC Ducts - Emit Odors
NO.: 24-21-93
GROUP: Air Conditioning
DATE: Sep. 3, 1993
SUBJECT: Air Conditioning Ducts Emits Odor
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS**
MODELS: 1992**- 1993**
(AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX)
1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX)
SYMPTOM/CONDITION:
Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when
the A/C system is first turned on.
Two causes for A/C related odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES
**On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally
results in an excessive amount of corrosion protection coating being applied on the evaporator
external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when
dry fins become wet from condensation.
To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the
appropriate service manual for the replacement procedure.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended
use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more
likely to occur in vehicles that have been in extended use in humid climates. To correct this
condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair
procedure outlined in this bulletin.
PARTS AND EQUIPMENT REQUIRED:
VEHICLES WITH LESS THAN 12,000 MILES
1 Coil, A/C Evaporator
AS 1992 4723069
AS 1993 - 1994 4474842
AC & AY 4677011
VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
1 A/C Evaporator Cleaner 4728942
1 Reusable Applicator 4740319
1 Pair Of Rubber Gloves
1 Pair Of Safety Glasses
REPAIR PROCEDURE:
This bulletin involves cleaning and disinfecting the A/C evaporator and housing.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 6943
- WEAR SAFETY GLASSES AND GLOVES
- AVOID BREATHING VAPORS
- USE WATER TO FLUSH EYES IF NECESSARY
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if
necessary.
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open
all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the
evaporator coil.
4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block.
**NOTE:
THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL
LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING
THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.**
5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at
least 80 PSI of pressure, to the reusable applicator.
6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
7. Turn the vehicle OFF and allow to soak for at least 30 minutes.
8. Wipe off any excess cleaner from around the instrument panel ducts.
9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF,
open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for
20 minutes to dry the system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
Replace Evaporator AC & AY 1992 - 1993
24-65-90-91 2.0 Hrs.
AS 1992 - 1994 24-65-90-91 2.4 Hrs.
Clean Evaporator AC, AS & AY 24-65-90-90
0.3 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front End Components
Front Of Engine Compartment, Front Of Radiator
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and
Inspection > Flow of Diagnosis
Blower Motor Diagnosis (Noise/Vibration)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and
Inspection > Flow of Diagnosis > Page 6952
Blower Motor Diagnosis (Electrical)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and
Inspection > Page 6953
Blower Motor: Service and Repair
1. Remove lower right instrument panel. 2. Remove blower housing mounting screws. 3. Allow
assembly to drop and remove from vehicle. 4. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description
and Operation
Blower Motor Relay: Description and Operation
Chrysler does not use a Blower Motor Relay for these Year/Make/Model Vehicles.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Blower Motor Resistor
RH Rear Corner Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical
Service Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose
Cabin Ventilation Duct: Customer Interest Left B Post Exhauster - Loose
NO: 23-59-94
GROUP: Body
DATE: Aug. 5, 1994
SUBJECT: Left "B"-Post Body Exhauster Retention
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may
cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with
very little assistance.
DIAGNOSIS:
Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the
repair procedure if the exhauster is loose of missing.
PARTS REQUIRED:
AR 82300234 Sealant, RTV
AR 4475320 Exhauster, Body
REPAIR PROCEDURE:
This bulletin involves adhering the "B"-post body exhauster to the "B"-post.
1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320.
2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side
flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration).
3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place.
4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may
have squeezed out from between the "B"-post body
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical
Service Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose >
Page 6968
exhauster and the "B"-post.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-89-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster Loose
Cabin Ventilation Duct: All Technical Service Bulletins Left B Post Exhauster - Loose
NO: 23-59-94
GROUP: Body
DATE: Aug. 5, 1994
SUBJECT: Left "B"-Post Body Exhauster Retention
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may
cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with
very little assistance.
DIAGNOSIS:
Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the
repair procedure if the exhauster is loose of missing.
PARTS REQUIRED:
AR 82300234 Sealant, RTV
AR 4475320 Exhauster, Body
REPAIR PROCEDURE:
This bulletin involves adhering the "B"-post body exhauster to the "B"-post.
1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320.
2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side
flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration).
3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place.
4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may
have squeezed out from between the "B"-post body
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster Loose > Page 6974
exhauster and the "B"-post.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-89-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 242593 > Dec > 93 > A/C
Compressor - Moaning Noise
Compressor Clutch: Customer Interest A/C Compressor - Moaning Noise
NO.: 24-25-93
GROUP: Air Conditioning
EFFECTIVE DATE: Dec. 31, 1993
SUBJECT: A/C Related Moan
MODELS:
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country
SYMPTOM/CONDITION:
A moan noise is heard in 1400 - 2000 engine RPM range when the A/C compressor is engaged.
This moan is the result of a resonance of components of the vehicle.
DIAGNOSIS:
Operate the engine in the 1400 - 2000 RPM range and engage the A/C compressor. If a moan
noise is heard, perform the repair procedure.
PARTS REQUIRED:
1 4773165 Clutch Plate, A/C with Damper Ring
AR 4462924 Shim Package, A/C Compressor Clutch
REPAIR PROCEDURE:
This bulletin involves replacing the A/C clutch plate with one that incorporates a damper ring.
NOTE: THIS REPAIR MAY NOT TOTALLY ELIMINATE THE MOAN BUT WILL REDUCE THE
NOISE SIGNIFICANTLY.
1. Remove the screw attaching the coolant recovery bottle and set the bottle aside to improve
access to the front of the A/C compressor.
2. Remove the compressor shaft bolt. A band type oil filter wrench can be placed around the clutch
plate to aid in bolt removal.
CAUTION: DO NOT USE ANY TYPE OF PRYING DEVICE BETWEEN THE CLUTCH PLATE
AND THE PULLEY TO REMOVE THE CLUTCH PLATE AS DAMAGE TO THE CLUTCH PLATE
OR PULLEY COULD RESULT.
3. Remove the clutch plate. It may be necessary to lightly tap the clutch plate with a plastic hammer
in order to free it from the compressor shaft.
4. Remove the clutch shim(s) from the shaft and clutch plate. Reinstall the shim(s) in the new
clutch plate.
5. Install the damper ring clutch plate (P/N 4773165) on the compressor shaft.
6. With the clutch plate pressed tight against the shim(s), measure the air gap between the clutch
plate and the pulley face with a feeler gauge. The air gap should be .020 in. - .035 in. (0.5 mm - 0.9
mm). Adjust the shim pack if necessary to obtain the proper air gap using shims (P/N 4462924).
7. Install and torque the compressor shaft bolt to 135 - 175 In.Lbs. (15.5 - 19.5 N-m).
8. The shims may compress after tightening the shaft bolt. Check the air gap in four or more places
to verify the air gap is still correct. Spin the pulley for the final check.
9. Reinstall the coolant recovery bottle.
NOTE: BECAUSE THIS REPAIR PROCEDURE REPLACES ONLY THE A/C COMPRESSOR
CLUTCH PLATE AND DOES NOT INCLUDE REPLACEMENT OF THE PULLEY, THE CLUTCH
PULLEY BREAK-IN PROCEDURE OUTLINED IN THE SERVICE MANUAL MUST BE MODIFIED
TO CYCLE THE A/C CLUTCH FIFTY (50) TIMES. OTHERWISE FOLLOW THE PROCEDURE
EXACTLY.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 242593 > Dec > 93 > A/C
Compressor - Moaning Noise > Page 6984
10. Perform the CLUTCH BREAK-IN procedure outlined on page 24-18 of the 1993 Van/Wagon
Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) or page 24-20 of
the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
24-05-16-90 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 242593 > Dec > 93 >
A/C Compressor - Moaning Noise
Compressor Clutch: All Technical Service Bulletins A/C Compressor - Moaning Noise
NO.: 24-25-93
GROUP: Air Conditioning
EFFECTIVE DATE: Dec. 31, 1993
SUBJECT: A/C Related Moan
MODELS:
1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country
SYMPTOM/CONDITION:
A moan noise is heard in 1400 - 2000 engine RPM range when the A/C compressor is engaged.
This moan is the result of a resonance of components of the vehicle.
DIAGNOSIS:
Operate the engine in the 1400 - 2000 RPM range and engage the A/C compressor. If a moan
noise is heard, perform the repair procedure.
PARTS REQUIRED:
1 4773165 Clutch Plate, A/C with Damper Ring
AR 4462924 Shim Package, A/C Compressor Clutch
REPAIR PROCEDURE:
This bulletin involves replacing the A/C clutch plate with one that incorporates a damper ring.
NOTE: THIS REPAIR MAY NOT TOTALLY ELIMINATE THE MOAN BUT WILL REDUCE THE
NOISE SIGNIFICANTLY.
1. Remove the screw attaching the coolant recovery bottle and set the bottle aside to improve
access to the front of the A/C compressor.
2. Remove the compressor shaft bolt. A band type oil filter wrench can be placed around the clutch
plate to aid in bolt removal.
CAUTION: DO NOT USE ANY TYPE OF PRYING DEVICE BETWEEN THE CLUTCH PLATE
AND THE PULLEY TO REMOVE THE CLUTCH PLATE AS DAMAGE TO THE CLUTCH PLATE
OR PULLEY COULD RESULT.
3. Remove the clutch plate. It may be necessary to lightly tap the clutch plate with a plastic hammer
in order to free it from the compressor shaft.
4. Remove the clutch shim(s) from the shaft and clutch plate. Reinstall the shim(s) in the new
clutch plate.
5. Install the damper ring clutch plate (P/N 4773165) on the compressor shaft.
6. With the clutch plate pressed tight against the shim(s), measure the air gap between the clutch
plate and the pulley face with a feeler gauge. The air gap should be .020 in. - .035 in. (0.5 mm - 0.9
mm). Adjust the shim pack if necessary to obtain the proper air gap using shims (P/N 4462924).
7. Install and torque the compressor shaft bolt to 135 - 175 In.Lbs. (15.5 - 19.5 N-m).
8. The shims may compress after tightening the shaft bolt. Check the air gap in four or more places
to verify the air gap is still correct. Spin the pulley for the final check.
9. Reinstall the coolant recovery bottle.
NOTE: BECAUSE THIS REPAIR PROCEDURE REPLACES ONLY THE A/C COMPRESSOR
CLUTCH PLATE AND DOES NOT INCLUDE REPLACEMENT OF THE PULLEY, THE CLUTCH
PULLEY BREAK-IN PROCEDURE OUTLINED IN THE SERVICE MANUAL MUST BE MODIFIED
TO CYCLE THE A/C CLUTCH FIFTY (50) TIMES. OTHERWISE FOLLOW THE PROCEDURE
EXACTLY.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 242593 > Dec > 93 >
A/C Compressor - Moaning Noise > Page 6990
10. Perform the CLUTCH BREAK-IN procedure outlined on page 24-18 of the 1993 Van/Wagon
Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) or page 24-20 of
the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
24-05-16-90 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > Page 6991
Compressor Clutch: Testing and Inspection
Compressor & Clutch Diagnosis (Part 2 of 2)
COMPRESSOR CLUTCH TEST
The air-conditioning compressor clutch electrical circuit is controlled by the engine controller
computer. It is located in the engine compartment outboard of the battery. If the compressor clutch
does not engage, Verify refrigerant charge. If the compressor clutch still does not engage, Check
for battery voltage at the differential pressure cut-off switch located on the expansion valve. If
voltage is detected at the cut-off switch, connect switch and check for battery voltage between the
compressor clutch connector terminals. If voltage is detected, perform A/C Clutch Coil Tests.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > Page 6992
CLUTCH COIL TESTS
1. Verify battery state of charge. (Test indicator in battery should be green). 2. Connect an
ammeter (0-10 ampere scale) in series with the clutch coil terminal. Use a volt meter (0-20 volt
scale) with clip leads measuring
voltage across the battery and A/C clutch.
3. With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle.
4. The A/C clutch should engage immediately and the clutch voltage should be within two volts of
the battery voltage. If the A/C clutch does not
engage, test the fusible link.
5. The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at
clutch coil. This is with the work area temperature
at 21°C (70°F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical
accessories until voltage reads below 12.5 volts.
If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4
amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within two
volts of the battery voltage, test clutch coil feed circuit for excessive voltage drop.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > Page 6993
Compressor Clutch: Service and Repair
Compressor Shaft Bolt And Clutch Plate
REMOVAL
NOTE: Compressor assembly must be removed from mounting. Although, refrigerant removal is
not necessary.
1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the
clutch plate to aid in bolt removal.
CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
Clutch Plate And Shims
2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > Page 6994
Removing Pulley Snap Ring
3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off
of compressor. 4. Remove coil wire clip screw and wire harness.
Clutch Coil Snap Ring
5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor
housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and
front plate should be replaced if there is excessive wear or
scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and
remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is
leaking and will have to be replaced.
7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has
contaminated the faces of the pulley or front plate, they
should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly.
CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing
operation. No attempt should be made to separately replace either part. This will result in clutch
slippage due to insufficient contact area.
INSTALLATION
1. Align pin in back of field coil with hole in compressor end housing, and position field coil into
place. Make sure that lead wires are properly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > Page 6995
routed, and fasten with the wire clip screw.
2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing
outward. Also both snap ring eyelets must be to the
right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the
groove.
CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
Installing Pulley Assembly
3. Install pulley assembly to compressor. If necessary; tap gently with a block of wood on the
friction surface.
CAUTION: Do not mar the pulley frictional surface.
4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the
snap ring to make sure it is properly seated in the
groove.
5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 1 mm
(0.040 in.) thick, on the shaft against the shoulder.
6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s),
measure the air gap between front plate and pulley face with feeler gauges. The air gap
should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or
subtract shims until desired air gap is obtained.
8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 Nm (135 to 175 in-lbs.).
NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to
verify if air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After a new clutch has been installed, check the voltage and amperage to the clutch (determine it
to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For
this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000.
This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch
torque capability.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair
Compressor Clutch Coil: Service and Repair
Compressor Shaft Bolt And Clutch Plate
REMOVAL
NOTE: Compressor assembly must be removed from mounting. Although, refrigerant removal is
not necessary.
1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the
clutch plate to aid in bolt removal.
CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
Clutch Plate And Shims
2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > Page 6999
Removing Pulley Snap Ring
3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off
of compressor. 4. Remove coil wire clip screw and wire harness.
Clutch Coil Snap Ring
5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor
housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and
front plate should be replaced if there is excessive wear or
scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and
remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is
leaking and will have to be replaced.
7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has
contaminated the faces of the pulley or front plate, they
should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly.
CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing
operation. No attempt should be made to separately replace either part. This will result in clutch
slippage due to insufficient contact area.
INSTALLATION
1. Align pin in back of field coil with hole in compressor end housing, and position field coil into
place. Make sure that lead wires are properly
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > Page 7000
routed, and fasten with the wire clip screw.
2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing
outward. Also both snap ring eyelets must be to the
right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the
groove.
CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
Installing Pulley Assembly
3. Install pulley assembly to compressor. If necessary; tap gently with a block of wood on the
friction surface.
CAUTION: Do not mar the pulley frictional surface.
4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the
snap ring to make sure it is properly seated in the
groove.
5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 1 mm
(0.040 in.) thick, on the shaft against the shoulder.
6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s),
measure the air gap between front plate and pulley face with feeler gauges. The air gap
should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or
subtract shims until desired air gap is obtained.
8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 Nm (135 to 175 in-lbs.).
NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to
verify if air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After a new clutch has been installed, check the voltage and amperage to the clutch (determine it
to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For
this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000.
This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch
torque capability.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations
Compressor Clutch Relay: Locations
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Page 7004
In Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Page 7005
Compressor Clutch Relay: Description and Operation
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Page 7006
In Power Distribution Center
PURPOSE
Supplies ground path for A/C compressor clutch.
OPERATION
Controlled by A/C or defrost switch (inside vehicle) and Powertrain Control Module (PCM). Relay
receives battery voltage from radiator fan relay , (A/C relay will not energize unless the radiator fan
relay is energized).
When A/C or defrost is selected, (turned ON), inside vehicle, and low and high pressure switches
are closed, PCM receives an A/C ON signal. PCM then supplies relay ground.
If PCM senses Wide Open Throttle (WOT) or low idle speed condition, it removes relay ground,
discontinueing A/C clutch engagement.
PCM delays activation of A/C relay for a specific period after engine start-up.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications
Condenser HVAC: Specifications
The oil designated for this vehicle is ND8 PAG (polyalkalene glycol).
Front A/C
- Condenser 15 ml (0.5 oz)
Dual A/C
- Condenser 30 ml (1.0 oz)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 7010
Condenser HVAC: Service and Repair
REMOVAL
WARNING: The refrigeration system must be completely empty before proceeding with this
operation.
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
1. Disconnect condenser to drier line at condenser side. 2. Remove radiator fan and shroud
assembly. 3. Remove condenser outlet to radiator bracket. 4. Remove grill assembly. 5. Remove
core support center brace. 6. Remove auxiliary transmission oil cooler, if equipped. 7. Remove
right side headlamp assembly. 8. Remove core support plastic panel. 9. Remove condenser
mounting bolts.
10. Remove condenser from vehicle.
INSTALLATION
1. To install, replace all 0-rings and gaskets, coat all sealing surfaces with approved wax-free
refrigerant oil. Then reverse the preceding operation. 2. Evacuate and charge system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Locations
Condenser Fan: Locations
Engine Compartment Component.
RH Front Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information
> Locations
Condenser Fan Motor Relay: Locations
Engine Compartment Components
RH Side Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 7025
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 7031
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 7032
Control Assembly: Locations
Instrument Panel Components & Connectors
Center Of Instrument Panel
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 7033
Control Assembly: Service and Repair
A/C AND HEATER CONTROL / BLOWER SWITCH
REMOVAL
(1) Remove the Center Instrument Panel Cluster Bezel.
(2) Remove cigar lighter element.
(3) Remove two screws and pull control assembly rearward. Reach behind control and disconnect
the wiring harnesses, vacuum lines and temperature
control cable (Fig. 1O) Remove switch.
(4) For installation reverse above procedures.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor
Evaporator Case: Customer Interest Air Conditioning Ducts - Emits Musty Odor
NO: 24-06-95 Rev. A
GROUP: Heater & A/C
DATE: May 26, 1995
SUBJECT: Air Conditioning Ducts Emit Odor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION
NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS: 1994 - 1995
(AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX)
1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX)
1993 - 1995 (AN) Dakota
1992 - 1995 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH
01-31-XX)
1994 - 1995 (BR) Ram Truck
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision
1995 (PL) Neon
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts.
The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related
odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some
vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an
excessive amount of corrosion protection coating being applied on the evaporator external
surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins
become wet from condensation. A new coating has been developed to correct this condition. The
evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive
odors from air conditioners can sometimes occur in vehicles that have been in extended use
resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely
to occur in vehicles that have been in extended use in humid climates. To correct this condition, the
internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair
Procedure B.
PARTS AND EQUIPMENT REQUIRED:
REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR
4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993)
AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992)
AR 4798624 Coil, A/C Evaporator (AN 1993-1995)
AR 4723069 Coil, A/C Evaporator (AS 1992)
AR 4734292 Coil, A/C Evaporator (AS 1993-1994)
AR 4797131 Coil, A/C Evaporator (AS 1995)
AR 4723518 Coil, A/C Evaporator (BR 1994)
AR 4798705 Coil, A/C Evaporator (BR 1995)
AR 4644790 Coil, A/C Evaporator (JA 1995)
AR 4797129 Coil, A/C Evaporator (LH 1993-1995)
AR 4797130 Coil, A/C Evaporator (PL 1995)
AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994)
AR 4798705 Coil, A/C Evaporator (ZJ 1995)
REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1
4728942 A/C Evaporator Cleaner
1 4740319 Reusable Applicator
1 NPN Pair of Rubber Gloves
1 NPN Pair of Safety Glasses
REPAIR PROCEDURE A:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7042
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7043
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor
Evaporator Case: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor
NO: 24-06-95 Rev. A
GROUP: Heater & A/C
DATE: May 26, 1995
SUBJECT: Air Conditioning Ducts Emit Odor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION
NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS: 1994 - 1995
(AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX)
1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX)
1993 - 1995 (AN) Dakota
1992 - 1995 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH
01-31-XX)
1994 - 1995 (BR) Ram Truck
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision
1995 (PL) Neon
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts.
The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related
odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some
vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an
excessive amount of corrosion protection coating being applied on the evaporator external
surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins
become wet from condensation. A new coating has been developed to correct this condition. The
evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive
odors from air conditioners can sometimes occur in vehicles that have been in extended use
resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely
to occur in vehicles that have been in extended use in humid climates. To correct this condition, the
internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair
Procedure B.
PARTS AND EQUIPMENT REQUIRED:
REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR
4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993)
AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992)
AR 4798624 Coil, A/C Evaporator (AN 1993-1995)
AR 4723069 Coil, A/C Evaporator (AS 1992)
AR 4734292 Coil, A/C Evaporator (AS 1993-1994)
AR 4797131 Coil, A/C Evaporator (AS 1995)
AR 4723518 Coil, A/C Evaporator (BR 1994)
AR 4798705 Coil, A/C Evaporator (BR 1995)
AR 4644790 Coil, A/C Evaporator (JA 1995)
AR 4797129 Coil, A/C Evaporator (LH 1993-1995)
AR 4797130 Coil, A/C Evaporator (PL 1995)
AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994)
AR 4798705 Coil, A/C Evaporator (ZJ 1995)
REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1
4728942 A/C Evaporator Cleaner
1 4740319 Reusable Applicator
1 NPN Pair of Rubber Gloves
1 NPN Pair of Safety Glasses
REPAIR PROCEDURE A:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor >
Page 7049
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor >
Page 7050
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Evaporator Case: > 085394 > Oct > 94 > Engine Starter - Intermittent No
Crank
Battery Cable: All Technical Service Bulletins Engine Starter - Intermittent No Crank
NO: 08-53-94
GROUP: Electrical
DATE: Oct. 7, 1994
SUBJECT: Intermittent No Crank
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
Engine intermittently will not crank.
DIAGNOSIS:
Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is
not fully seated, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the battery to starter cable terminal insulator at the starter
connection.
1. Record the customers preset radio station selections.
2. Disconnect the ground cable from the battery.
3. Remove the battery to starter cable from the starter.
4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration.
5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the
illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat
flush.
6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Evaporator Case: > 085394 > Oct > 94 > Engine Starter - Intermittent No
Crank > Page 7056
7. Connect the ground cable to the battery.
8. Reprogram the customers preset radio stations and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-90-12-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Evaporator Case: > 085394 > Oct > 94 > Engine Starter - Intermittent No
Crank > Page 7062
7. Connect the ground cable to the battery.
8. Reprogram the customers preset radio stations and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-90-12-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Page 7063
Evaporator Case: Service and Repair
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL AND INSTALLATION
WARNING: If equipped with air conditioning, the refrigeration system must be completely empty
before proceeding.
CAUTION: Disconnect battery negative cable, in engine compartment, before servicing instrument
panel.
1. Set parking brake. 2. Disconnect battery negative cable. 3. Using a refrigerant recovery
machine, remove refrigerant from the A/C system. 4. Disconnect all engine compartment lines and
vacuum hoses. 5. Drain engine coolant. Plug coolant lines.
INSTRUMENT PANEL CLUSTER BEZEL
1. To remove top cover use a flat blade tool. Pry up on either end and continue across the full
length of the top cover. 2. To remove cluster bezel grille use the removal tool. Using tool at either
end pull up and remove grille. 3. Remove six mounting screws from the hood and message center
assembly. Using a flat blade tool pry up on either end and remove module and
disconnect wire connector.
4. Reach behind lower right corner of center bezel and pull to disconnect attaching clip. Repeat in
all of the corners and remove bezel. Disconnect
ash receiver wire and lamp assembly if equipped.
5. Remove three instrument cluster bezel screws on the bottom of bezel and three at the upper left.
Pulling up and rearward on the top edge of bezel
remove bezel.
6. Disconnect POD switches wiring connectors.
LOWER RIGHT INSTRUMENT PANEL
Steering Column Cover
1. Remove steering column cover. 2. Remove premium console. 3. Remove center trim bezel.
Remove ash receiver lamp and socket if equipped. 4. Remove A/C heater control. 5. Disconnect
cigar lighter. 6. Remove screw in air duct.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Page 7064
Glove Box
7. Remove attaching screws and right lower panel. Screw location:
- One screw outboard right of lower panel
- Two screws in ash receiver/cupholder opening
- Two screws bottom on the lower right
- One screw in heater duct above heater control.
- Remove glove box attaching screws and disconnect check straps.
- Disconnect glove box lamp.
INSTRUMENT PANEL REMOVAL
WARNING: Chock wheels when instrument panel is to be rolled down. The steering column is
removed and transmission may be out of park. Release the park brake before the release cable is
disconnected. Disconnecting park brake cable while park brake is engaged may cause personal
injury.
Silencer Panel
1. Remove lower left instrument panel silencer. 2. Set parking brake and shift gear selector into
low. 3. Remove lower left reinforcement. 4. Disconnect transmission range indicator at column. 5.
Unhook transmission range indicator cable eyelet from column actuating arm:
- Release column insert lock tab.
- Squeeze legs together and lift insert from steering column, leave insert free.
- Place cable on instrument panel to avoid transmission range indicator cable damage during
removal.
6. Remove steering column. See: Steering and Suspension/Steering/Steering Column/Service and
Repair 7. Remove lower right instrument panel silencer. 8. Remove floor braces. 9. Remove
A-pillar intermediate and sill scuff garnish moldings.
10. Unfasten the hood release mechanism from the side cowl. 11. Disconnect the brake light
switch, parking brake switch and bulk head wiring connectors. 12. Under the hood disconnect the
ABS connector and resistor block. Unseat the grommet at the dash panel and feed wiring back into
passenger
compartment.
13. Remove the two nuts, securing the instrument panel, at the steering column support brace. 14.
Loosen the instrument panel roll up bolts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Page 7065
15. Remove the six screws securing the instrument panel at the fence line. 16. Roll the instrument
panel back and hang it from the short position of the roll up hook. 17. With instrument panel
hanging in the short position disconnect the left side body wiring connections. 18. Roll the
instrument panel to the long position on the roll up hook and perform the following operations:
- Disconnect the antenna cable.
- Disconnect the blower motor lead connection.
- Disconnect the temperature control cable from the A/C or heater unit.
- Disconnect the vacuum lines from the climate control assembly
- Disconnect the right side body wiring connectors.
19. Remove instrument panel from vehicle. 20. Disconnect the A/C unit hanger strap from the unit
and temporarily reposition. 21. Remove the rubber condensate drain tube (in engine compartment).
22. Remove the four nuts (in the engine compartment) securing the unit to the dash panel. 23. Pull
the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it
rearward to remove it from vehicle.
To install the assembly, reverse the preceding operation.
NOTE: When installing cluster, do not kink or bind transmission range indicator guide tube and
position guide tube in original location. Move shift lever to Neutral (N) and note pointer location.
Move shift lever to D, L and P note pointer location. Adjust, if necessary to center pointer on N.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor
Evaporator Core: Customer Interest Air Conditioning Ducts - Emits Musty Odor
NO: 24-06-95 Rev. A
GROUP: Heater & A/C
DATE: May 26, 1995
SUBJECT: Air Conditioning Ducts Emit Odor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION
NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS: 1994 - 1995
(AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX)
1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX)
1993 - 1995 (AN) Dakota
1992 - 1995 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH
01-31-XX)
1994 - 1995 (BR) Ram Truck
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision
1995 (PL) Neon
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts.
The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related
odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some
vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an
excessive amount of corrosion protection coating being applied on the evaporator external
surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins
become wet from condensation. A new coating has been developed to correct this condition. The
evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive
odors from air conditioners can sometimes occur in vehicles that have been in extended use
resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely
to occur in vehicles that have been in extended use in humid climates. To correct this condition, the
internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair
Procedure B.
PARTS AND EQUIPMENT REQUIRED:
REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR
4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993)
AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992)
AR 4798624 Coil, A/C Evaporator (AN 1993-1995)
AR 4723069 Coil, A/C Evaporator (AS 1992)
AR 4734292 Coil, A/C Evaporator (AS 1993-1994)
AR 4797131 Coil, A/C Evaporator (AS 1995)
AR 4723518 Coil, A/C Evaporator (BR 1994)
AR 4798705 Coil, A/C Evaporator (BR 1995)
AR 4644790 Coil, A/C Evaporator (JA 1995)
AR 4797129 Coil, A/C Evaporator (LH 1993-1995)
AR 4797130 Coil, A/C Evaporator (PL 1995)
AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994)
AR 4798705 Coil, A/C Evaporator (ZJ 1995)
REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1
4728942 A/C Evaporator Cleaner
1 4740319 Reusable Applicator
1 NPN Pair of Rubber Gloves
1 NPN Pair of Safety Glasses
REPAIR PROCEDURE A:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7074
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7075
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise
Evaporator Core: Customer Interest A/C Evaporator - High Pitched Whistle Noise
NO: 24-12-94
GROUP: Heater & A/C
DATE: Jul. 8, 1994
SUBJECT: A/C Evaporator High Pitch Whistle
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3,
1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN
24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL
(PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE
BULLETIN 24-12-94.
MODELS:
1993 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE
PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE
CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN
VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED
VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE
OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L
ENGINE EQUIPPED VEHICLES.
SYMPTOM/CONDITION:
Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some
evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The
whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch
engages. The duration and the intensity of the whistle noise may vary as well as be highly
intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85
degrees Fahrenheit and engine speeds around 2000 RPM.
DIAGNOSIS:
Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient
temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the
vehicle owner describe in detail the condition(s) in which they experience their concern to
determine if this bulletin applies.
PARTS REQUIRED:
1 4677334 Valve, A/C Expansion
1 4677045 Gasket, A/C Expansion Valve To Evaporator
1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a different type of expansion valve.
1. Recover the R-134a refrigerant while completely discharging the A/C system.
WARNING:
THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS
OPERATION.
2. Remove the boot-type wire connector from the low pressure cut-off switch.
3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS).
4. Remove the bolt in the center of the refrigerant line sealing plate.
5. Carefully pull the refrigerant line sealing plate from the expansion valve.
6. Cover the openings on refrigerant line sealing plate to prevent contamination.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise > Page 7080
7. Remove the two screws attaching the expansion valve to the evaporator sealing plate.
8. Carefully remove the expansion valve and the two aluminum gaskets.
9. Place a new gasket (P/N 4677045) on the evaporator sealing plate.
10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO
NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m).
11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate.
12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH
THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.).
13. Connect the wire connectors to the low pressure cut-off switch and the ECCS.
14. Evacuate and recharge the A/C system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-35-20-90 0.8 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest: > 242193 > Sep > 93 > AC Ducts - Emit Odors
Evaporator Core: Customer Interest AC Ducts - Emit Odors
NO.: 24-21-93
GROUP: Air Conditioning
DATE: Sep. 3, 1993
SUBJECT: Air Conditioning Ducts Emits Odor
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS**
MODELS: 1992**- 1993**
(AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX)
1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX)
SYMPTOM/CONDITION:
Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when
the A/C system is first turned on.
Two causes for A/C related odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES
**On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally
results in an excessive amount of corrosion protection coating being applied on the evaporator
external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when
dry fins become wet from condensation.
To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the
appropriate service manual for the replacement procedure.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended
use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more
likely to occur in vehicles that have been in extended use in humid climates. To correct this
condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair
procedure outlined in this bulletin.
PARTS AND EQUIPMENT REQUIRED:
VEHICLES WITH LESS THAN 12,000 MILES
1 Coil, A/C Evaporator
AS 1992 4723069
AS 1993 - 1994 4474842
AC & AY 4677011
VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
1 A/C Evaporator Cleaner 4728942
1 Reusable Applicator 4740319
1 Pair Of Rubber Gloves
1 Pair Of Safety Glasses
REPAIR PROCEDURE:
This bulletin involves cleaning and disinfecting the A/C evaporator and housing.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 7085
- WEAR SAFETY GLASSES AND GLOVES
- AVOID BREATHING VAPORS
- USE WATER TO FLUSH EYES IF NECESSARY
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if
necessary.
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open
all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the
evaporator coil.
4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block.
**NOTE:
THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL
LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING
THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.**
5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at
least 80 PSI of pressure, to the reusable applicator.
6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
7. Turn the vehicle OFF and allow to soak for at least 30 minutes.
8. Wipe off any excess cleaner from around the instrument panel ducts.
9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF,
open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for
20 minutes to dry the system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
Replace Evaporator AC & AY 1992 - 1993
24-65-90-91 2.0 Hrs.
AS 1992 - 1994 24-65-90-91 2.4 Hrs.
Clean Evaporator AC, AS & AY 24-65-90-90
0.3 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits
Musty Odor
Evaporator Core: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor
NO: 24-06-95 Rev. A
GROUP: Heater & A/C
DATE: May 26, 1995
SUBJECT: Air Conditioning Ducts Emit Odor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION
NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS: 1994 - 1995
(AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX)
1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX)
1993 - 1995 (AN) Dakota
1992 - 1995 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH
01-31-XX)
1994 - 1995 (BR) Ram Truck
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision
1995 (PL) Neon
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts.
The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related
odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some
vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an
excessive amount of corrosion protection coating being applied on the evaporator external
surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins
become wet from condensation. A new coating has been developed to correct this condition. The
evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive
odors from air conditioners can sometimes occur in vehicles that have been in extended use
resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely
to occur in vehicles that have been in extended use in humid climates. To correct this condition, the
internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair
Procedure B.
PARTS AND EQUIPMENT REQUIRED:
REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR
4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993)
AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992)
AR 4798624 Coil, A/C Evaporator (AN 1993-1995)
AR 4723069 Coil, A/C Evaporator (AS 1992)
AR 4734292 Coil, A/C Evaporator (AS 1993-1994)
AR 4797131 Coil, A/C Evaporator (AS 1995)
AR 4723518 Coil, A/C Evaporator (BR 1994)
AR 4798705 Coil, A/C Evaporator (BR 1995)
AR 4644790 Coil, A/C Evaporator (JA 1995)
AR 4797129 Coil, A/C Evaporator (LH 1993-1995)
AR 4797130 Coil, A/C Evaporator (PL 1995)
AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994)
AR 4798705 Coil, A/C Evaporator (ZJ 1995)
REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1
4728942 A/C Evaporator Cleaner
1 4740319 Reusable Applicator
1 NPN Pair of Rubber Gloves
1 NPN Pair of Safety Glasses
REPAIR PROCEDURE A:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits
Musty Odor > Page 7091
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits
Musty Odor > Page 7092
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 241794 > Nov > 94 > A/C - Evaporator Freezes Up/Lack
Of Cooling
Evaporator Core: All Technical Service Bulletins A/C - Evaporator Freezes Up/Lack Of Cooling
NO.: 24-17-94
GROUP: Heater & A/C
DATE: Nov. 18, 1994
SUBJECT: A/C Evaporator Freeze-Up or Lack of Cooling on Cycling Clutch A/C Systems (Fixed
Displacement Compressor)
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-17-92 DATED DEC. 14,
1992 WHICH SHOULD BE NOTED IN YOUR FILES. THE REVISION CONSISTS OF
ADDITIONAL MODELS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
DISCUSSION:
A loss of A/C airflow and/or cooling while the A/C blower fan continues to operate may be
experienced on some of the above vehicles.
The electrical signal from the A/C cycling clutch switch passes through the Powertrain Control
Module (PCM) to engage and disengage the A/C clutch relay. If the PCM is not properly
disengaging the A/C clutch via the relay, the compressor will stay on continuously and result in
evaporator freeze-up. Also, the PCM may not energize the A/C clutch relay at all. This condition
results in the lack of cooling from the A/C system.
The PCM should be checked per the procedure in the appropriate Powertrain Diagnostic
Procedure Manual. Diagnostic Trouble Code 33 (A/C clutch relay circuit) will be present when
either of these conditions are caused by the PCM. It is important to perform the complete test
sequence because there are other A/C clutch relay circuit components that could also cause or
contribute to the condition.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle
Noise
Evaporator Core: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle Noise
NO: 24-12-94
GROUP: Heater & A/C
DATE: Jul. 8, 1994
SUBJECT: A/C Evaporator High Pitch Whistle
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3,
1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN
24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL
(PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE
BULLETIN 24-12-94.
MODELS:
1993 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE
PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE
CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN
VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED
VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE
OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L
ENGINE EQUIPPED VEHICLES.
SYMPTOM/CONDITION:
Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some
evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The
whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch
engages. The duration and the intensity of the whistle noise may vary as well as be highly
intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85
degrees Fahrenheit and engine speeds around 2000 RPM.
DIAGNOSIS:
Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient
temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the
vehicle owner describe in detail the condition(s) in which they experience their concern to
determine if this bulletin applies.
PARTS REQUIRED:
1 4677334 Valve, A/C Expansion
1 4677045 Gasket, A/C Expansion Valve To Evaporator
1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a different type of expansion valve.
1. Recover the R-134a refrigerant while completely discharging the A/C system.
WARNING:
THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS
OPERATION.
2. Remove the boot-type wire connector from the low pressure cut-off switch.
3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS).
4. Remove the bolt in the center of the refrigerant line sealing plate.
5. Carefully pull the refrigerant line sealing plate from the expansion valve.
6. Cover the openings on refrigerant line sealing plate to prevent contamination.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle
Noise > Page 7101
7. Remove the two screws attaching the expansion valve to the evaporator sealing plate.
8. Carefully remove the expansion valve and the two aluminum gaskets.
9. Place a new gasket (P/N 4677045) on the evaporator sealing plate.
10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO
NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m).
11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate.
12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH
THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.).
13. Connect the wire connectors to the low pressure cut-off switch and the ECCS.
14. Evacuate and recharge the A/C system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-35-20-90 0.8 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 242193 > Sep > 93 > AC Ducts - Emit Odors
Evaporator Core: All Technical Service Bulletins AC Ducts - Emit Odors
NO.: 24-21-93
GROUP: Air Conditioning
DATE: Sep. 3, 1993
SUBJECT: Air Conditioning Ducts Emits Odor
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS**
MODELS: 1992**- 1993**
(AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX)
1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town &
Country
1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX)
SYMPTOM/CONDITION:
Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when
the A/C system is first turned on.
Two causes for A/C related odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES
**On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally
results in an excessive amount of corrosion protection coating being applied on the evaporator
external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when
dry fins become wet from condensation.
To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the
appropriate service manual for the replacement procedure.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended
use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more
likely to occur in vehicles that have been in extended use in humid climates. To correct this
condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair
procedure outlined in this bulletin.
PARTS AND EQUIPMENT REQUIRED:
VEHICLES WITH LESS THAN 12,000 MILES
1 Coil, A/C Evaporator
AS 1992 4723069
AS 1993 - 1994 4474842
AC & AY 4677011
VEHICLES IN SERVICE FOR 12 MONTHS OR MORE
1 A/C Evaporator Cleaner 4728942
1 Reusable Applicator 4740319
1 Pair Of Rubber Gloves
1 Pair Of Safety Glasses
REPAIR PROCEDURE:
This bulletin involves cleaning and disinfecting the A/C evaporator and housing.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 7106
- WEAR SAFETY GLASSES AND GLOVES
- AVOID BREATHING VAPORS
- USE WATER TO FLUSH EYES IF NECESSARY
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if
necessary.
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open
all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the
evaporator coil.
4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block.
**NOTE:
THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL
LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING
THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.**
5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at
least 80 PSI of pressure, to the reusable applicator.
6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
7. Turn the vehicle OFF and allow to soak for at least 30 minutes.
8. Wipe off any excess cleaner from around the instrument panel ducts.
9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF,
open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for
20 minutes to dry the system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
Replace Evaporator AC & AY 1992 - 1993
24-65-90-91 2.0 Hrs.
AS 1992 - 1994 24-65-90-91 2.4 Hrs.
Clean Evaporator AC, AS & AY 24-65-90-90
0.3 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Core: > 241794 > Nov > 94 > A/C - Evaporator Freezes Up/Lack Of
Cooling
Evaporator Core: All Technical Service Bulletins A/C - Evaporator Freezes Up/Lack Of Cooling
NO.: 24-17-94
GROUP: Heater & A/C
DATE: Nov. 18, 1994
SUBJECT: A/C Evaporator Freeze-Up or Lack of Cooling on Cycling Clutch A/C Systems (Fixed
Displacement Compressor)
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-17-92 DATED DEC. 14,
1992 WHICH SHOULD BE NOTED IN YOUR FILES. THE REVISION CONSISTS OF
ADDITIONAL MODELS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
DISCUSSION:
A loss of A/C airflow and/or cooling while the A/C blower fan continues to operate may be
experienced on some of the above vehicles.
The electrical signal from the A/C cycling clutch switch passes through the Powertrain Control
Module (PCM) to engage and disengage the A/C clutch relay. If the PCM is not properly
disengaging the A/C clutch via the relay, the compressor will stay on continuously and result in
evaporator freeze-up. Also, the PCM may not energize the A/C clutch relay at all. This condition
results in the lack of cooling from the A/C system.
The PCM should be checked per the procedure in the appropriate Powertrain Diagnostic
Procedure Manual. Diagnostic Trouble Code 33 (A/C clutch relay circuit) will be present when
either of these conditions are caused by the PCM. It is important to perform the complete test
sequence because there are other A/C clutch relay circuit components that could also cause or
contribute to the condition.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Page 7112
Evaporator Core: Specifications
The oil designated for this vehicle is ND8 PAG (polyalkalene glycol).
Front A/C
- Evaporator 30 ml (1.0 oz)
Dual A/C
- Evaporator 60 ml (2.0 oz)
- Rear Evap. 60 ml (2.0 oz)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL AND INSTALLATION
WARNING: If equipped with air conditioning, the refrigeration system must be completely empty
before proceeding.
CAUTION: Disconnect battery negative cable, in engine compartment, before servicing instrument
panel.
1. Set parking brake. 2. Disconnect battery negative cable. 3. Using a refrigerant recovery
machine, remove refrigerant from the A/C system. 4. Disconnect all engine compartment lines and
vacuum hoses. 5. Drain engine coolant. Plug coolant lines.
INSTRUMENT PANEL CLUSTER BEZEL
1. To remove top cover use a flat blade tool. Pry up on either end and continue across the full
length of the top cover. 2. To remove cluster bezel grille use the removal tool. Using tool at either
end pull up and remove grille. 3. Remove six mounting screws from the hood and message center
assembly. Using a flat blade tool pry up on either end and remove module and
disconnect wire connector.
4. Reach behind lower right corner of center bezel and pull to disconnect attaching clip. Repeat in
all of the corners and remove bezel. Disconnect
ash receiver wire and lamp assembly if equipped.
5. Remove three instrument cluster bezel screws on the bottom of bezel and three at the upper left.
Pulling up and rearward on the top edge of bezel
remove bezel.
6. Disconnect POD switches wiring connectors.
LOWER RIGHT INSTRUMENT PANEL
Steering Column Cover
1. Remove steering column cover. 2. Remove premium console. 3. Remove center trim bezel.
Remove ash receiver lamp and socket if equipped. 4. Remove A/C heater control. 5. Disconnect
cigar lighter. 6. Remove screw in air duct.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 7115
Glove Box
7. Remove attaching screws and right lower panel. Screw location:
- One screw outboard right of lower panel
- Two screws in ash receiver/cupholder opening
- Two screws bottom on the lower right
- One screw in heater duct above heater control.
- Remove glove box attaching screws and disconnect check straps.
- Disconnect glove box lamp.
INSTRUMENT PANEL REMOVAL
WARNING: Chock wheels when instrument panel is to be rolled down. The steering column is
removed and transmission may be out of park. Release the park brake before the release cable is
disconnected. Disconnecting park brake cable while park brake is engaged may cause personal
injury.
Silencer Panel
1. Remove lower left instrument panel silencer. 2. Set parking brake and shift gear selector into
low. 3. Remove lower left reinforcement. 4. Disconnect transmission range indicator at column. 5.
Unhook transmission range indicator cable eyelet from column actuating arm:
- Release column insert lock tab.
- Squeeze legs together and lift insert from steering column, leave insert free.
- Place cable on instrument panel to avoid transmission range indicator cable damage during
removal.
6. Remove steering column.See: Steering and Suspension/Steering/Steering Column/Service and
Repair 7. Remove lower right instrument panel silencer. 8. Remove floor braces. 9. Remove
A-pillar intermediate and sill scuff garnish moldings.
10. Unfasten the hood release mechanism from the side cowl. 11. Disconnect the brake light
switch, parking brake switch and bulk head wiring connectors. 12. Under the hood disconnect the
ABS connector and resistor block. Unseat the grommet at the dash panel and feed wiring back into
passenger
compartment.
13. Remove the two nuts, securing the instrument panel, at the steering column support brace. 14.
Loosen the instrument panel roll up bolts.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 7116
15. Remove the six screws securing the instrument panel at the fence line. 16. Roll the instrument
panel back and hang it from the short position of the roll up hook. 17. With instrument panel
hanging in the short position disconnect the left side body wiring connections. 18. Roll the
instrument panel to the long position on the roll up hook and perform the following operations:
- Disconnect the antenna cable.
- Disconnect the blower motor lead connection.
- Disconnect the temperature control cable from the A/C or heater unit.
- Disconnect the vacuum lines from the climate control assembly
- Disconnect the right side body wiring connectors.
19. Remove instrument panel from vehicle. 20. Disconnect the A/C unit hanger strap from the unit
and temporarily reposition. 21. Remove the rubber condensate drain tube (in engine compartment).
22. Remove the four nuts (in the engine compartment) securing the unit to the dash panel. 23. Pull
the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it
rearward to remove it from vehicle.
DISASSEMBLY
1. Place heater A/C unit assembly on workbench. 2. Remove one screw at the vacuum harness.
Feed harness through hole in cover. 3. Remove thirteen screws from top cover and remove cover.
Temperature control door will come out with the cover. Remove the nut and lever from
the door shaft to remove the temperature door from the cover.
Heater Core
4. Remove screw from heater core tube retaining bracket and lift heater core out of unit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 7117
A/C Evaporator
5. Remove A/C evaporator coil out of unit.
6 Disconnect actuator linkage from fresh-recirculation door and vacuum lines from actuator.
Loosen two nuts at actuator to housing and remove actuator.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 7118
7 Remove four screws at fresh-recirculation cover to unit and lift off cover.
8 Fresh/recirculating door may now be removed from its housing.
9 To remove heat defrost door, remove clip from shaft inside the housing. Pull shaft from housing
and remove door.
10 To remove mode door, remove clip from shaft inside the housing. Pull the shaft from the
housing and remove door.
ASSEMBLY
1. Place evaporator coil into unit. 2. Place heater core into unit and fasten with screws. 3. Reinstall
blower wheel onto blower motor shaft and secure with retaining clamp. 4. Feed blower motor wires
through hole in housing. Lower blower assembly (rubber seal in place) into housing. Pull wiring
grommet into place and
install three mounting screws.
5. Install blower motor assembly (five screws) to housing. 6. Install fresh/recirculating door into
housing. Install fresh/recirculating cover (four screws). Rotate actuator shaft into door and slide
actuator into
bracket and tighten two nuts.
7. To install mode door to housing, insert door shaft through housing and door pivot and demister
spring. Push on shaft retainer 8. To install demister door, connect wire spring to demister door.
Insert pivot end of door into hole in housing. Position opposite into slot. 9. To install heat/defrost
door, insert door shaft through housing and door pivot. Push on shaft retainer.
10. Install heat distribution duct to bottom of housing with three screws. 11. To install temperature
control door, install door shaft into lower pivot in the case housing. Place unit cover over housing
while feeding temperature
door shaft through cover. If the temperature control door is attached to the cover, feed the door into
the housing with the cover. Direct the bottom pivot of the door with your hand through the mode
door opening.
12. To install housing cover, line up cover to housing using pilot pins, the temperature door; and
screw holes for alignment. Install thirteen screws. 13. Route vacuum harness through holes in
cover. Install screw to retain vacuum harness. Make all vacuum hose attachments to vacuum
actuators.
NOTE: When installing cluster, do not kink or bind transmission range indicator guide tube and
position guide tube in original location. Move shift lever to Neutral (N) and note pointer location.
Move shift lever to D, L and P note pointer location. Adjust, if necessary to center pointer on N.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 7119
Evaporator Core: Service and Repair Rear Evaporator and Expansion Valve Replacement
REMOVE
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
WARNING: On vehicles equipped with rear A/C, the refrigerant system must be emptied before
performing the following operation. The engine cooling system must also be relieved of all
pressure.
Rear Heater Plumbing
1. Drain engine cooling system. Disconnect heater hoses at rear heater A/C unit.
Rear A/C Plumbing
2. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C
plumbing from rear heater A/C unit. 3. Remove left lower quarter trim panel. 4. Remove screws
securing air distribution duct to the rear wheel housing. 5. Remove screws securing heater unit to
the floor pan. 6. Remove screw securing unit to the quarter panel support. 7. Lift the unit enough to
clear floor pan. Remove unit from the vehicle.
EVAPORATOR AND EXPANSION VALVE
1. Remove unit cover. 2. Remove the bolt that mounts the unified refrigerant plumbing block to the
expansion valve. 3. Carefully pull the evaporator and expansion valve straight out of unit.
CAUTION: Do not scratch the sealing surfaces with the plumbing extension tube pilots.
4. Remove and discard the aluminum gasket between the plumbing extension and the expansion
valve.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 7120
5. Cover the plumbing extension sealing surface to prevent contamination. 6. Bring evaporator and
expansion valve to a clean work space. 7. Remove two 1/4-20 Torx Head screws. 8. Remove
expansion valve. 9. Measure and record the amount of residual oil from the removed evaporator.
INSTALL
1. Replace the aluminum gaskets. 2. Hold expansion valve against evaporator sealing plate
CAUTION: Do not scratch the sealing surface.
3. Install two screws and tighten to 70 to 130 inch pounds (8 to 14 Nm). 4. Carefully install the
evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the
plumbing extension tube
pilots.
5. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system. 6. Carefully align the expansion valve onto the pilot tube
of the plumbing sealing plate (do not scratch the sealing surface). Install the bolt through
the plumbing plate into the unit sealing plate. Tighten bolts to 170 to 230 inch pounds (20 to 26
Nm).
7. Install unit cover and air distribution duct. 8. Install quarter trim panel, evacuate/charge system,
and test performance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits
Musty Odor
Evaporator Drain Tube: Customer Interest Air Conditioning Ducts - Emits Musty Odor
NO: 24-06-95 Rev. A
GROUP: Heater & A/C
DATE: May 26, 1995
SUBJECT: Air Conditioning Ducts Emit Odor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION
NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS: 1994 - 1995
(AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX)
1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX)
1993 - 1995 (AN) Dakota
1992 - 1995 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH
01-31-XX)
1994 - 1995 (BR) Ram Truck
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision
1995 (PL) Neon
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts.
The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related
odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some
vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an
excessive amount of corrosion protection coating being applied on the evaporator external
surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins
become wet from condensation. A new coating has been developed to correct this condition. The
evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive
odors from air conditioners can sometimes occur in vehicles that have been in extended use
resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely
to occur in vehicles that have been in extended use in humid climates. To correct this condition, the
internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair
Procedure B.
PARTS AND EQUIPMENT REQUIRED:
REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR
4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993)
AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992)
AR 4798624 Coil, A/C Evaporator (AN 1993-1995)
AR 4723069 Coil, A/C Evaporator (AS 1992)
AR 4734292 Coil, A/C Evaporator (AS 1993-1994)
AR 4797131 Coil, A/C Evaporator (AS 1995)
AR 4723518 Coil, A/C Evaporator (BR 1994)
AR 4798705 Coil, A/C Evaporator (BR 1995)
AR 4644790 Coil, A/C Evaporator (JA 1995)
AR 4797129 Coil, A/C Evaporator (LH 1993-1995)
AR 4797130 Coil, A/C Evaporator (PL 1995)
AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994)
AR 4798705 Coil, A/C Evaporator (ZJ 1995)
REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1
4728942 A/C Evaporator Cleaner
1 4740319 Reusable Applicator
1 NPN Pair of Rubber Gloves
1 NPN Pair of Safety Glasses
REPAIR PROCEDURE A:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits
Musty Odor > Page 7129
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits
Musty Odor > Page 7130
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning
Ducts - Emits Musty Odor
Evaporator Drain Tube: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor
NO: 24-06-95 Rev. A
GROUP: Heater & A/C
DATE: May 26, 1995
SUBJECT: Air Conditioning Ducts Emit Odor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION
NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS: 1994 - 1995
(AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX)
1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX)
1993 - 1995 (AN) Dakota
1992 - 1995 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH
01-31-XX)
1994 - 1995 (BR) Ram Truck
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision
1995 (PL) Neon
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts.
The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related
odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some
vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an
excessive amount of corrosion protection coating being applied on the evaporator external
surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins
become wet from condensation. A new coating has been developed to correct this condition. The
evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive
odors from air conditioners can sometimes occur in vehicles that have been in extended use
resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely
to occur in vehicles that have been in extended use in humid climates. To correct this condition, the
internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair
Procedure B.
PARTS AND EQUIPMENT REQUIRED:
REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR
4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993)
AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992)
AR 4798624 Coil, A/C Evaporator (AN 1993-1995)
AR 4723069 Coil, A/C Evaporator (AS 1992)
AR 4734292 Coil, A/C Evaporator (AS 1993-1994)
AR 4797131 Coil, A/C Evaporator (AS 1995)
AR 4723518 Coil, A/C Evaporator (BR 1994)
AR 4798705 Coil, A/C Evaporator (BR 1995)
AR 4644790 Coil, A/C Evaporator (JA 1995)
AR 4797129 Coil, A/C Evaporator (LH 1993-1995)
AR 4797130 Coil, A/C Evaporator (PL 1995)
AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994)
AR 4798705 Coil, A/C Evaporator (ZJ 1995)
REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1
4728942 A/C Evaporator Cleaner
1 4740319 Reusable Applicator
1 NPN Pair of Rubber Gloves
1 NPN Pair of Safety Glasses
REPAIR PROCEDURE A:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning
Ducts - Emits Musty Odor > Page 7136
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning
Ducts - Emits Musty Odor > Page 7137
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Customer Interest for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise
Expansion Valve: Customer Interest A/C Evaporator - High Pitched Whistle Noise
NO: 24-12-94
GROUP: Heater & A/C
DATE: Jul. 8, 1994
SUBJECT: A/C Evaporator High Pitch Whistle
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3,
1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN
24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL
(PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE
BULLETIN 24-12-94.
MODELS:
1993 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE
PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE
CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN
VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED
VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE
OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L
ENGINE EQUIPPED VEHICLES.
SYMPTOM/CONDITION:
Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some
evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The
whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch
engages. The duration and the intensity of the whistle noise may vary as well as be highly
intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85
degrees Fahrenheit and engine speeds around 2000 RPM.
DIAGNOSIS:
Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient
temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the
vehicle owner describe in detail the condition(s) in which they experience their concern to
determine if this bulletin applies.
PARTS REQUIRED:
1 4677334 Valve, A/C Expansion
1 4677045 Gasket, A/C Expansion Valve To Evaporator
1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a different type of expansion valve.
1. Recover the R-134a refrigerant while completely discharging the A/C system.
WARNING:
THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS
OPERATION.
2. Remove the boot-type wire connector from the low pressure cut-off switch.
3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS).
4. Remove the bolt in the center of the refrigerant line sealing plate.
5. Carefully pull the refrigerant line sealing plate from the expansion valve.
6. Cover the openings on refrigerant line sealing plate to prevent contamination.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Customer Interest for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise >
Page 7146
7. Remove the two screws attaching the expansion valve to the evaporator sealing plate.
8. Carefully remove the expansion valve and the two aluminum gaskets.
9. Place a new gasket (P/N 4677045) on the evaporator sealing plate.
10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO
NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m).
11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate.
12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH
THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.).
13. Connect the wire connectors to the low pressure cut-off switch and the ECCS.
14. Evacuate and recharge the A/C system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-35-20-90 0.8 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched
Whistle Noise
Expansion Valve: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle Noise
NO: 24-12-94
GROUP: Heater & A/C
DATE: Jul. 8, 1994
SUBJECT: A/C Evaporator High Pitch Whistle
NOTE:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3,
1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN
24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL
(PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE
BULLETIN 24-12-94.
MODELS:
1993 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE
PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE
CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN
VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED
VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE
OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L
ENGINE EQUIPPED VEHICLES.
SYMPTOM/CONDITION:
Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some
evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The
whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch
engages. The duration and the intensity of the whistle noise may vary as well as be highly
intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85
degrees Fahrenheit and engine speeds around 2000 RPM.
DIAGNOSIS:
Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient
temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the
vehicle owner describe in detail the condition(s) in which they experience their concern to
determine if this bulletin applies.
PARTS REQUIRED:
1 4677334 Valve, A/C Expansion
1 4677045 Gasket, A/C Expansion Valve To Evaporator
1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a different type of expansion valve.
1. Recover the R-134a refrigerant while completely discharging the A/C system.
WARNING:
THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS
OPERATION.
2. Remove the boot-type wire connector from the low pressure cut-off switch.
3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS).
4. Remove the bolt in the center of the refrigerant line sealing plate.
5. Carefully pull the refrigerant line sealing plate from the expansion valve.
6. Cover the openings on refrigerant line sealing plate to prevent contamination.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched
Whistle Noise > Page 7152
7. Remove the two screws attaching the expansion valve to the evaporator sealing plate.
8. Carefully remove the expansion valve and the two aluminum gaskets.
9. Place a new gasket (P/N 4677045) on the evaporator sealing plate.
10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO
NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m).
11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate.
12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH
THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.).
13. Connect the wire connectors to the low pressure cut-off switch and the ECCS.
14. Evacuate and recharge the A/C system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-35-20-90 0.8 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Page 7153
Expansion Valve: Service and Repair
REMOVE
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
WARNING: On vehicles equipped with rear A/C, the refrigerant system must be emptied before
performing the following operation. The engine cooling system must also be relieved of all
pressure.
Rear Heater Plumbing
1. Drain engine cooling system. Disconnect heater hoses at rear heater A/C unit.
Rear A/C Plumbing
2. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C
plumbing from rear heater A/C unit. 3. Remove left lower quarter trim panel. 4. Remove screws
securing air distribution duct to the rear wheel housing. 5. Remove screws securing heater unit to
the floor pan. 6. Remove screw securing unit to the quarter panel support. 7. Lift the unit enough to
clear floor pan. Remove unit from the vehicle.
EVAPORATOR AND EXPANSION VALVE
1. Remove unit cover. 2. Remove the bolt that mounts the unified refrigerant plumbing block to the
expansion valve. 3. Carefully pull the evaporator and expansion valve straight out of unit.
CAUTION: Do not scratch the sealing surfaces with the plumbing extension tube pilots.
4. Remove and discard the aluminum gasket between the plumbing extension and the expansion
valve. 5. Cover the plumbing extension sealing surface to prevent contamination. 6. Bring
evaporator and expansion valve to a clean work space.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Page 7154
7. Remove two 1/4-20 Torx Head screws. 8. Remove expansion valve. 9. Measure and record the
amount of residual oil from the removed evaporator.
INSTALL
1. Replace the aluminum gaskets. 2. Hold expansion valve against evaporator sealing plate
CAUTION: Do not scratch the sealing surface.
3. Install two screws and tighten to 70 to 130 inch pounds (8 to 14 Nm). 4. Carefully install the
evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the
plumbing extension tube
pilots.
5. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system. 6. Carefully align the expansion valve onto the pilot tube
of the plumbing sealing plate (do not scratch the sealing surface). Install the bolt through
the plumbing plate into the unit sealing plate. Tighten bolts to 170 to 230 inch pounds (20 to 26
Nm).
7. Install unit cover and air distribution duct. 8. Install quarter trim panel, evacuate/charge system,
and test performance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core
Heater Core: Service and Repair Front Heater Core
1. Set parking brake and disconnect battery ground cable. 2. Discharge and recover system
refrigerant. 3. Disconnect all engine compartment heater and air conditioning lines and vacuum
hoses. 4. Drain engine coolant and plug lines. 5. Remove instrument panel as described in
Instrument Panel/Service and Repair/Dash Panel Replacement. 6. Disconnect air conditioning
hanger strap and temporarily reposition. 7. Remove rubber condensate drain tube and four
mounting nuts in engine compartment.
Fig. 10 A/C & Heater Assembly
8. Pull heater/air conditioning assembly to rear until unit studs clear dash panel, then drop unit
down and remove from vehicle. 9. Place heater/air conditioning assembly on suitable workbench,
then remove screw at vacuum harness and feed harness through hole in cover.
10. Remove thirteen screws from top cover, then remove top cover. 11. Remove screw from heater
core tube retaining bracket, then lift heater core out of unit. 12. Remove evaporator core from unit.
13. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core > Page 7159
Heater Core: Service and Repair Rear Heater Core
REMOVE AND INSTALL
1. Drain the engine coolant system.
Rear Heater Plumbing
2. Disconnect heater tubing from the underbody heater lines to the rear unit. 3. Remove the lower
left quarter trim panel. 4. Remove fan A/C distribution duct. 5. Remove heater-unit cover. 6.
Carefully pull the heater core and heater tubes straight out of the unit. 7. Raise the heater core to
drain residual coolant from the core. 8. Disconnect two heater hose clamps that attach plumbing to
the heater core tube. 9. To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hoses
Heater Hose: Service and Repair Heater Hoses
Review Safety Precautions and Warnings the in General Information section before proceeding
with this operation.
1. Drain engine cooling system.
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peal off heater hose. This method will require heater hose replacement.
To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hoses > Page 7165
Heater Hose: Service and Repair Underbody Plumbing
WARNING: THE ENGINE COOLING SYSTEM MUST BE RELIEVED OF ALL PRESSURE.
1. Drain the engine cooling system.
2. In the engine compartment, and disconnect two auxiliary rear heater hoses from the (front)
heater hose tee fittings.
3. Hoist the vehicle. Disconnect two push-together couplings from the auxiliary rear heater core
tubes protruding through the floor pan.
4. Remove four bolts and one pal nut holding the plumbing to the floor pan and lower the plumbing
from the vehicle.
To Install, Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > A/C Hose - Squeaking Noise
Hose/Line HVAC: Technical Service Bulletins A/C Hose - Squeaking Noise
NO: 24-02-94
GROUP: Heat & A/C
DATE: Jan. 14, 1994
SUBJECT: Squeak in Right Shock Tower Area
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right
shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in
the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn
through, a squeak may occur under driving conditions. Inspect the hose and bracket area and
relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Page 7170
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Removal and Installation
Hose/Line HVAC: Service and Repair Removal and Installation
REMOVAL (1) Recover A/C system. (2) Remove upper generator bracket. See: Starting and
Charging/Charging System. (3) Remove ground wire at cowl.
(4) Remove expansion valve plate and bolt (Fig.50. (5) Remove liquid line from expansion valve.
(6) Remove wire connector at pressure transducer. (7) Remove liquid line mounting bracket at right
frame rail. (8) Using access slot between radiator crossmember arid grille, loosen liquid line
mounting plate at filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to remove line. The replacement Tine is a two-piece
assembly.
INSTALLATION (1) To install, reverse preceding operation. Replace all O-rings. Install two-piece
line in place of original part. Assemble line halves after it is installed
on vehicle.
(2) Evacuate and recharge A/C system.
SUCTION LINE
REMOVAL (1) Recover A/C system.
(2) Remove suction line mounting nut at compressor (Fig. 51). (3) Remove upper generator
bracket. See: Starting and Charging/Charging System (4) Remove ground wire at cowl.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Removal and Installation > Page 7173
(5) Remove expansion valve line plate nut (Fig.52). (6) Remove suction line mounting bracket. (7)
Remove suction line.
INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and
recharge A/C system.
DISCHARGE LINE
REMOVAL (1) Recover A/C system
(2) Remove discharge line mounting nut at compressor (Fig. 53).
(3) Remove discharge line at the top fitting on the condenser (Fig. 54).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Removal and Installation > Page 7174
INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and
recharge A/C system. (3) Perform HVAC Control calibration and test procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Removal and Installation > Page 7175
Hose/Line HVAC: Service and Repair Rear Air Conditioning Lines
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE
FOLLOWING OPERATION.
1. Hoist the vehicle. Disconnect two tube-fittings from the engine compartment plumbing.
2. Remove the bolt from the unified plumbing block (left side of car, outboard of rail, forward of fuel
tank).
3. Carefully pull refrigerant line assembly down (take care NOT to scratch the sealing surface with
the tube pilots). Remove and discard the
aluminum gasket and cover unit sealing surface to prevent contamination.
4. Remove two screws holding plumbing to the fuel tank support and left-side support rail (near
muffler support bracket).
5. Remove two screws holding the plumbing to the floor pan.
6. Disconnect the parking brake system at hook above muffler and the cable connection near the
support rails.
7. Fish the nylon tubing and unified plumbing block above the muffler support member.
8. Lower the plumbing from the vehicle.
9. Measure the residual oil in the under body plumbing out of each end of the plumbing. The
lowside (larger diameter line) has a check valve that can
restrict oil flow from the tube-fitting to the unified plumbing end of the hose. Measure clean R134a
PAG refrigerant oil to be returned to the refrigerant system.
INSTALL
1. Protect the plumbing ends from scratches. If plumbing is new, do not remove the shipping caps
until joining together.
2. Reverse the preceding steps from the REMOVAL procedure.
3. New gaskets and O-rings are required for installation. The O-rings must be covered with clean
refrigerant oil prior to installation.
4. Connect the tube-fittings to the engine compartment under body plumbing. Avoid misalignment
of the threads (cross threading) and tighten to 200
in-lbs
5. Remove the shipping cap from the plumbing side sealing surface and verify that the aluminum
gasket is present.
6. Carefully align the pilot tubes of the plumbing line block into the unit (take care not to scratch the
sealing surface).
7. Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolt to 200 +/- 30 in
lbs (23 +/- 3 Nm).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair
Housing Assembly HVAC: Service and Repair
REMOVE AND INSTALL
WARNING: On vehicles equipped with rear A/C, the refrigerant system must be discharged before
performing the following operation. The engine cooling system must also be relieved of all
pressure.
Rear Heater Plumbing
Rear A/C Plumbing
1. Drain engine cooling system. Disconnect heater hoses at rear heater-A/C unit. 2. Discharge
refrigerant system. Disconnect A/C plumbing from rear heater-A/C unit.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Page 7179
Rear Heater-A/C Components
3. Remove left lower quarter trim panel. 4. Remove the attaching screws securing the air
distribution duct to the rear wheel housing. 5. Remove the attaching screws securing the heater
unit to the floor pan. 6. Remove attaching screw securing the unit to the quarter panel support. 7.
Lift the unit enough to clear the floor pan and remove the unit from the vehicle.
To Install, Reverse the preceding operation. Install new gaskets at refrigerant lines and expansion
valve. Evacuate and charge the refrigerant system. Refill the cooling system. Test for leaks and
overall performance.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications
Receiver Dryer: Specifications
The oil designated for this vehicle is ND8 PAG (polyalkalene glycol).
Front A/C
- Filter-Drier 15 ml (0.5 oz)
Dual A/C
- Filter-Drier 30 ml (1.0 oz)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > R 134A Refrigerant - Leak Detection Systems
Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection Systems
NO.: 24-20-93
GROUP: Air Conditioning
DATE: Jul. 30, 1993
SUBJECT: R-134A Refrigerant Leak Detection
MODELS:
DISCUSSION:
Numerous R-134A leak detection units are on the market. Some units are better than others, and
keep in mind R-134A is more difficult to detect than R-12 because of R-134A's smaller molecular
structure. Listed below are the R-134A leak detection units currently approved by Chrysler:
HITECH Instruments models HI 300 TEL, HI 350, HI 400 NOVA TEL, and HI 450 NOVA.
Leybold Inficon models HLD4000 and D/TEC.
OTC/Yokogawa model H10N.
All Jeep/Eagle dealers were shipped R-134A equipment in March 1992 to be able to service the ZJ
products and Chrysler/Plymouth/Dodge dealers were shipped the same equipment in May 1993. A
HITECH Instruments, Model HI 300 TEL leak detector, was included in these equipment packages.
Use of any other R-134A leak detection equipment will lead to improper diagnosis, repeat repairs
and customer dissatisfaction. HITECH Instruments Models are available through Professional
Service Equipment.
Points to keep in mind when performing R-134A leak detection:
* Testing should be performed 5-7 minutes after A/C system has be turned off.
* The hood should be raised at least 5 minutes prior to performing leak detection. This is to help
ensure any accumulation of R-134A can dissipate and prevent detecting false leaks throughout the
engine compartment.
* The probe should be moved at a rate of 1-2 inches per second and no more than 1/2 inch from
the surface being checked. DO NOT HOLD THE PROBE IN ONE LOCATION OR ALLOW THE
PROBE TO TOUCH ANY SURFACE OR LIQUID. Doing so may contaminate the probe and cause
false readings.
* Probe along the bottom side of the components because R-134A is heavier than air.
* Leak detector probes are very sensitive to contaminants. Do not expose probes to lubricants,
paint, welding and mastic fumes, vehicle fuel, exhaust or coolant, halogenated solvents,
chlorinated water or steam, dust, powder, or direct streams of R-12 or R-134A. Contaminants
cause false readings.
* Always follow the leak detector manufacturer's instructions very closely.
* A properly maintained and calibrated APPROVED LEAK DETECTOR is your best tool for
accurate leak detection and customer satisfaction.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > R 134A Refrigerant - Leak Detection Systems > Page 7187
Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection
NO.: 24-13-94
GROUP: Air Conditioning
DATE: Sep. 9, 1994
SUBJECT: R-134a Refrigerant Leak Detection
MODELS:
1994 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1994 - 1995 (AB) Ram Van/Ram Wagon
1994 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1994 - 1995 (AN) Dakota/Dakota Cab & Chassis
1994 (AP) Shadow/Sundance
1993 - 1995 (AS) Caravan/Voyager/Town & Country
1994 (BD) Laser/Talon (Midyear Change)
1994 - 1995 (BR) Ram Truck
1994 - 1995 (B7) Stealth
1994 - 1995 (B8) Colt Vista/Summit Wagon
1994 - 1995 (B9) Colt/Summit
1994 - 1995 (ES) Chrysler Voyager (Export Only)
1995 (FJ) Avenger/Sebring/Talon
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
1995 (PL) Neon
1993 - 1995 (SR) Viper
1994 - 1995 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
R-134a refrigerant leaks are more difficult to detect than R-12 because of the smaller molecular
structure. Listed below are the R-134a leak detection units currently approved by Chrysler and
SAE:
HITECH Instruments Models HI 300 TEL, H1350, HI 400 NOVA TEL, and Hi 450 NOVA
Leybold Inficon Models HLD4000 and D/TEC
OTC/Yokogawa Model H10N
NOTE:
LEAK DETECTOR PROBES ARE VERY SENSITIVE TO CONTAMINANTS. DO NOT EXPOSE
PROBES TO LUBRICANTS, PAINT, WELDING AND MASTIC FUMES, VEHICLE FUEL,
EXHAUST OR COOLANT, HALOGENATED SOLVENTS, CHLORINATED WATER OR STEAM,
DUST, POWDER, OR DIRECT STREAMS OF R-12 OR R134a. ANY TIME CONTAMINATION IS
VISUALLY PRESENT ON THE PROBE, OR THE PROBE IS SUSPECTED OF BEING NEAR A
CONTAMINANT, FOLLOW THE MANUFACTURERS RECOMMENDATION FOR CLEANING OR
REPLACING THE FILTER/SENSOR. ONLY A PROPERLY MAINTAINED LEAK DETECTOR WILL
PROVIDE ACCURATE LEAK DETECTION.
TECHNICIAN PROCEDURE FOR USING ELECTRONIC REFRIGERANT LEAK DETECTORS
FOR SERVICE OF MOBILE AIR CONDITIONING SYSTEMS
SAE Recommended Practice J1628
1. The electronic leak detector shall be operated in accordance with the equipment manufacturer's
operating instructions.
2. Leak test with the engine not in operation.
3. The air conditioning system shall be charged with sufficient refrigerant to have a gauge pressure
of at least 340 kPa (50 psi) when not in operation. At temperatures below 15~C (59~F), leaks may
not be measurable since this pressure may not be reached.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > R 134A Refrigerant - Leak Detection Systems > Page 7188
4. Take care not to contaminate the detector probe if the part being tested is contaminated. If the
part is particularly dirty, it should be wiped off with a dry shop towel or blown off with shop air. No
cleaners or solvents shall be used, since many electronic detectors are sensitive to their
ingredients.
5. Visually trace the entire refrigerant system and look for signs of air conditioning lubricant
leakage, damage, or corrosion on all lines, hoses, and components. Each questionable area
should be carefully checked with the detector probe, as well as all fittings, hose to line couplings,
refrigerant controls, service ports with caps off, brazed or welded areas, and areas around
attachment points and holddowns on lines and components.
6. Always follow the refrigerant system around in a continuous path so that no areas of potential
leaks are missed. If a leak is found, always continue to test the remainder of the system.
7. At each area checked, the probe should be moved around at a rate of no more than 25 to 50
mm/s (1 to 2 inches/second), and no more than 5 mm (1/4 in.) from the surface completely around
the position. Slower and closer movement of the probe greatly improves the likelihood of finding a
leak.
8. An apparent leak should be verified at least once by blowing shop air into the area of the
suspected leak, if necessary, and repeating the check of the area. In cases of very large leaks,
blowing out the area with shop air often helps locate the exact position of a leak.
9. Leak testing of the evaporator core while in the air conditioning module should be accomplished
by turning the air conditioning blower on high for a period of 15 seconds minimum, shutting it off,
then waiting for the refrigerant to accumulate in the case for time specified by 9.1, then inserting
the leak detector probe into the condensate drain hole if no water is present, or into the closest
opening in the heating/ventilation/air conditioning case to the evaporator, such as heat duct or vent
duct. If the detector alarms, a leak apparently has been found.
NOTE:
R134a REFRIGERANT IS HEAVIER THAN AIR AND WILL TEND TO STAY LOW IN THE A/C
MODULE.
9.1 The accumulation time shall be specified by the leak detector manufacturer in the instructions
included with the detector, or a minimum of 2 minutes.
10. Following any service to the refrigerant system of the vehicle, and any other service which
disturbs the refrigerant system, a leak test of the repair and of the service ports of the refrigerant
system should be done.
NOTE:
CURRENTLY THERE IS NO CHRYSLER APPROVED R-134A REFRIGERANT LEAK
DETECTION DYE AVAILABLE. USE OF AN UNAPPROVED DYE WILL CAUSE DAMAGE TO
THE A/C SYSTEM. AN APPROVED DYE WILL BE AVAILABLE IN THE NEAR FUTURE.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications
Refrigerant: Capacity Specifications
A/C System
With Rear AC .......................................................................................................................................
....................................................... 1.420 kg (50 oz)
Without Rear AC ..................................................................................................................................
...................................................... 1.020 kg (36 oz)
Capacities
Capacities
Capacity
2.25 lb (US)
Capacities
Capacities
Capacity
3.25 lb (US)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications > Page 7191
Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications
A/C Refrigerant Specifications
Refrigerant type
R134a
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications
Refrigerant Filter: Specifications
The oil designated for this vehicle is ND8 PAG (polyalkalene glycol).
Front A/C
- Filter-Drier 15 ml (0.5 oz)
Dual A/C
- Filter-Drier 30 ml (1.0 oz)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
A/C System
When all air conditioning system is first assembled, all components (except the compressor) are
refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and components.
The evaporator, condenser, and filter-drier will retain a significant amount of oil, see below. When a
component is replaced, the specified amount of refrigerant oil must be added.
When the compressor is replaced, the amount of oil that is retained in the rest of the system must
be drained from the replacement compressor. When a line or component has ruptured and oil has
escaped, the compressor should be removed and drained. The filter-drier must be replaced along
with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining
components, can be measured and poured into the suction port of the compressor.
EXAMPLE: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1
oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil.
220 ml minus 90 ml = 130 ml (4.40 oz).
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND-8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................. 142 ml (4.73 oz)
- Filter-Drier .........................................................................................................................................
................................................... 15 ml (0.5 oz)
- Condenser .........................................................................................................................................
..................................................... 15 ml (0.5 oz)
- Evaporator .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Capacities
Capacities
Ounces Viscosity
4.73 oz (US) ND8 PAG
Polyalkaline Glycol
Capacities
Capacities
Ounces Viscosity
7.40 oz (US) ND8 PAG
Polyalkaline Glycol
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 7199
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil
The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, Polyalkylene Glycol
(PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils,
and should never be introduced to an R-134a refrigerant system.
Refrigerant oil will absorb any moisture it comes in contact with, including moisture in the air. The
oil container should be kept tightly capped until it is ready to be used. Then, cap the oil immediately
after using, to prevent contamination.
There are different PAG oils available, and each contains a different additive package. The
refrigerant oil designated for this vehicle is ND-8 PAG . Use only refrigerant oil of this same type to
service the refrigerant system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
It will not be necessary to check the oil level in the compressor or add oil unless there has been an
oil loss. Oil loss at the leak point will be evident by the presence of a wet, shiny surface around the
leak. If a leak is detected and the compressor must be removed, it is not necessary to discharge
the system unless the refrigerant lines will be removed for service. If the lines will be removed,
discharge system as outlined in "System Diagnosis/Evacuating the A/C System" and note the
following procedure:
1. Disconnect battery ground cable. 2. Loosen and remove drive belts and disconnect compressor
clutch wire lead. 3. Remove refrigerant lines from compressor. 4. Remove compressor attaching
nuts and bolts. 5. From suction port on top of compressor, drain refrigerant oil from compressor. 6.
Install replacement components. 7. Add system capacity minus the capacity of components that
have not been replaced. 8. Reverse procedure to install. 9. Evacuate and recharge system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair
> Oil Charge Additions > Page 7202
Refrigerant Oil: Service and Repair Purging Compressor
The compressor must be purged of air whenever it has been isolated from the system for service.
1. Install oil plugs or reconnect refrigerant lines and manual valves to compressor as needed.
2. Cap service access ports on both manual valves, then rotate low (suction) side service valve
counterclockwise to the back-seated position.
3. Rotate high (discharge) side manual valve to mid-position, then slightly loosen cap on high side
gauge port to allow refrigerant to force air out of compressor.
4. Back seat high side manual valve, then tighten gauge port cap.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations
Engine Compartment Wiring
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch
Low Pressure Sensor / Switch: Locations Low Pressure Cut-Off Switch
The Low pressure cut-out switch (LPCO) is located on the expansion valve. The expansion valve is
silver in color.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch > Page 7211
Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch
The Electronic Cycling Clutch Switch (ECCS) is located on the A/C expansion valve at the rear of
engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 7212
Low Pressure Sensor / Switch: Description and Operation
The Low Pressure Cut-Off (LPCO) Switch monitors the refrigerant gas pressure on the suction side
of. the system. The LPCO is located on the expansion valve, and the expansion valve is silver in
color. The LPCO turns off voltage to the compressor clutch coil when refrigerant gas pressure
drops to levels that could damage the compressor. The LPCO is a sealed factory calibrated unit. It
must be replaced if defective.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 7213
Low Pressure Sensor / Switch: Testing and Inspection
Low Pressure Cut-off Switch
The work area temperature must not be below 10°C (50°F) to test the compressor clutch. circuit
1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise
hood and disconnect LPCO switch connector boot. 3. Using a suitable jumper wire, jump across
the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling
clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge
set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, LPCO switch will
complete the clutch circuit. If the low pressure gauge reads below 172 kPa (25 psi), the system is
low on refrigerant charge or empty due to a leak.
6. Install connector boot on switch and repeat step number 3. If the clutch does not engage,
replace the. LPCO switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement
Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement
Low Pressure Cut-Off Switch (LPCO)
REMOVAL AND INSTALLATION
WARNING: The refrigeration system must be completely empty before proceeding with this
operation.
1. Disconnect the boot like wire connector at the cut-off switch. 2. Using a sender unit type socket,
remove the switch from the expansion valve.
To insure an adequate seal on the switch, use a small amount of thread sealing tape. Reverse the
preceding steps.
Evacuate and charge the system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement >
Page 7216
Low Pressure Sensor / Switch: Service and Repair Low Pressure Cycling Clutch Switch
Replacement
Electronic Cycling Clutch Switch Combo Valve (ECCS)
REMOVAL AND INSTALLATION
1. Disconnect the 3 pin connector at the ECCS. 2. Remove 4 mm hex bolt from side of expansion
valve. 3. Slip the capillary tube from the well on the expansion valve. The capillary-tube-well is filled
with a special temperature conductive grease. Save
this special grease and reuse it when installing the new switch.
To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Description and Operation
Blower Motor Relay: Description and Operation
Chrysler does not use a Blower Motor Relay for these Year/Make/Model Vehicles.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Compressor Clutch Relay: Locations
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7224
In Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7225
Compressor Clutch Relay: Description and Operation
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7226
In Power Distribution Center
PURPOSE
Supplies ground path for A/C compressor clutch.
OPERATION
Controlled by A/C or defrost switch (inside vehicle) and Powertrain Control Module (PCM). Relay
receives battery voltage from radiator fan relay , (A/C relay will not energize unless the radiator fan
relay is energized).
When A/C or defrost is selected, (turned ON), inside vehicle, and low and high pressure switches
are closed, PCM receives an A/C ON signal. PCM then supplies relay ground.
If PCM senses Wide Open Throttle (WOT) or low idle speed condition, it removes relay ground,
discontinueing A/C clutch engagement.
PCM delays activation of A/C relay for a specific period after engine start-up.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
RH Side Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC >
Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Locations
Air Conditioning Switch: Locations
Heater A/C Controls
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Front Of Engine Compartment, Front Of Radiator
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
Engine Compartment Wiring
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Cut-Off
Switch
Low Pressure Sensor / Switch: Locations Low Pressure Cut-Off Switch
The Low pressure cut-out switch (LPCO) is located on the expansion valve. The expansion valve is
silver in color.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Cut-Off
Switch > Page 7248
Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch
The Electronic Cycling Clutch Switch (ECCS) is located on the A/C expansion valve at the rear of
engine compartment.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7249
Low Pressure Sensor / Switch: Description and Operation
The Low Pressure Cut-Off (LPCO) Switch monitors the refrigerant gas pressure on the suction side
of. the system. The LPCO is located on the expansion valve, and the expansion valve is silver in
color. The LPCO turns off voltage to the compressor clutch coil when refrigerant gas pressure
drops to levels that could damage the compressor. The LPCO is a sealed factory calibrated unit. It
must be replaced if defective.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7250
Low Pressure Sensor / Switch: Testing and Inspection
Low Pressure Cut-off Switch
The work area temperature must not be below 10°C (50°F) to test the compressor clutch. circuit
1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise
hood and disconnect LPCO switch connector boot. 3. Using a suitable jumper wire, jump across
the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling
clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge
set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, LPCO switch will
complete the clutch circuit. If the low pressure gauge reads below 172 kPa (25 psi), the system is
low on refrigerant charge or empty due to a leak.
6. Install connector boot on switch and repeat step number 3. If the clutch does not engage,
replace the. LPCO switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure
Cut-Out Switch Replacement
Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement
Low Pressure Cut-Off Switch (LPCO)
REMOVAL AND INSTALLATION
WARNING: The refrigeration system must be completely empty before proceeding with this
operation.
1. Disconnect the boot like wire connector at the cut-off switch. 2. Using a sender unit type socket,
remove the switch from the expansion valve.
To insure an adequate seal on the switch, use a small amount of thread sealing tape. Reverse the
preceding steps.
Evacuate and charge the system.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure
Cut-Out Switch Replacement > Page 7253
Low Pressure Sensor / Switch: Service and Repair Low Pressure Cycling Clutch Switch
Replacement
Electronic Cycling Clutch Switch Combo Valve (ECCS)
REMOVAL AND INSTALLATION
1. Disconnect the 3 pin connector at the ECCS. 2. Remove 4 mm hex bolt from side of expansion
valve. 3. Slip the capillary tube from the well on the expansion valve. The capillary-tube-well is filled
with a special temperature conductive grease. Save
this special grease and reuse it when installing the new switch.
To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations
Service Port HVAC: Locations
Discharge Valve Service Port
Suction Valve Service Port
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
DISARMING
1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at
least ten minutes after disconnecting battery ground cable before performing any further repairs on
vehicle. The SRS system is
designed to retain enough voltage to deploy air bag for a short time even after battery has been
disconnected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming > Page 7266
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
ARMING
1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side
of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one
is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning
light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate
SRS system is functioning correctly.
5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air
Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
Technical Service Bulletin # 818 Date: 990701
Recall - Inadvertent Airbag Deployment
July 1999
Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring
Models
1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service as determined by using the DIAL VIP System.
Subject
The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above
vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately
after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to
inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant.
Repair
A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag
system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve
replacing the clockspring). If the rear wiper motor must be replace.
Alternate Transportation
If inspection determines that clockspring and/or rear wiper motor replacement is required and the
vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by
placing the owner in a loaner vehicle.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
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Use one of the table labor operation numbers and time allowances shown.
Add the cost of the parts used plus applicable dealer allowance to your claim.
Use the labor operation number and time allowance shown if an owner requires replacement of a
rear wiper motor at some time in the future after the recall has already been completed.
Parts Return
If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be
returned for core credit as quickly as possible using the Mopar Core Return Procedure on your
DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select
Function 10.
If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the
Warranty Material Return Center.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing and material return instructions.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
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DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD818".
Owner Notification and Service Scheduling
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All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner notification letter is included.
Provided with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Parts Information
A. Mastic Patch
Part Number Description
55275444AB Mastic Patch
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Mastic Patches to service about 25% of those vehicles.
B. Clockspring Assembly Package
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Part Number Description
CCXR8181 Clockspring with Speed Control
CCLR8182 Clockspring without Speed Control
Each package contains a clockspring and a mastic patch.
Due to the small number of involved vehicles expected to require clockspring replacement, each
dealer will receive one clockspring for vehicles equipped with speed control. No clockspring
assemblies for vehicles without speed control will be distributed initially. Additional clockspring
packages should be ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require clockspring replacement.
C. Tie Strap/Clips and Heat Shrink Tubing
In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and
ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary.
Additional tie strap/clips and heat shrink tubing may be ordered as necessary.
D. Rear Wiper Motor Assembly
Part Number Description
R4673326 Remanufactured Rear Wiper Motor Assembly
OR
04673326 New Rear Wiper Motor Assembly
Due to the small number of involved vehicles expected to require rear wiper motor replacement, no
wiper motors will be distributed initially. Wiper motors should be ordered only after inspection
determines that replacement is required. Very few vehicles are expected to require rear wiper
motor replacement.
A. Install Mastic Patch & Check For Airbag System
Diagnostic Trouble Codes (DTC's):
1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off.
2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1).
3. Disconnect the liftgate release switch electrical connector (Figure 1).
4. Disconnect the parking hand brake linkage.
5. Set the lower steering column cover aside.
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6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure
2).
7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect
the DRB III to the underdash diagnostic connector (blue connector to the right of the steering
column) and power it up.
8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen.
9. Turn the ignition key tot he "ON" position.
10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN
MENU Screen.
12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen.
14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen.
15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen.
16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen.
17. Record all active DTC's for future reference.
18. Press the PAGE BACK key to return to the DTC TYPE Screen.
19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen.
20. Record all stored DTC's for future reference.
21. Press the PAGE BACK key to continue.
22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present).
23. Press the PAGE BACK key to continue.
24. Turn the ignition key off and disconnect the DRB III.
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25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the
table. If no airbag system DTC's exist, continue with Step 26.
NOTE:
Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any
airbag system diagnostic trouble codes other than those listed above.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Return the vehicle to the customer. No further action is necessary.
B. Replace Rear Wiper Motor
IMPORTANT:
This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the liftgate wiper arm assembly.
3. Open and raise the liftgate.
4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3).
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5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws
(Figure 3).
6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel
screws (Figure 3).
7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3).
8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and
remove the screws (Figure 3).
9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel
(Figure 3).
10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel
from the liftgate.
11. Disconnect the wiper motor electrical connector (Figure 4).
12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor
and bracket assembly from the liftgate and set it aside.
13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate.
Torque the five (5) attaching screws to 35 in-lbs (4 Nm).
14. Connect the wiper motor electrical connector.
15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter
of the panel.
16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3).
CAUTION:
DO NOT over tighten screws as this could damage the trim panel or strip the screws.
17. Install the two (2) screws located in the speaker grille openings (Figure 3).
18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3).
19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3).
20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs.
21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp
assemblies.
22. Close the liftgate.
23. Install the liftgate wiper arm assembly.
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24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse
(Fuse # 13) with a new 20 amp fuse (Figure 5).
25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be
repaired, continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Turn the ignition switch to the ON position and exit the vehicle.
31. Connect the negative battery terminal.
32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
C. Repair Driver Airbag Wiring and.or Replace Clockspring
IMPORTANT:
This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble
code.
1. Place the steering wheel in the straight ahead position.
2. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
3. Remove the upper and lower steering column shrouds.
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4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure
6).
^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5.
^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged,
repair the clockspring wires by taping the damaged area with high quality electrical tape and tie
strap as shown in Figure 6.
^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged,
replace the clockspring assembly as follows:
a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel,
disconnect the airbag module electrical connector and then remove the airbag module from the
steering wheel and set it aside (inflator side down/face up for safety).
b. Disconnect the speed control switch connector (if equipped).
c. Disconnect the horn connector.
d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool
C-3428B), remove the steering wheel.
e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring
pigtail from the steering column.
f. Disconnect the clockspring wiring connector from the back of the clockspring.
g. Unclip the clockspring assembly locating fingers from the steering column and then remove and
discard the clockspring.
h. Snap the new clockspring onto the steering column.
i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring
harness that connects to the ignition switch is between the pigtail and the steering column. Secure
the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6).
j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail
to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA)
(Figure 6).
k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm).
l. Connect the horn connector.
m. Connect the speed control switch connector (if equipped).
n. Connect the airbag module electrical connector and install the airbag module onto the steering
wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm).
5. Install the upper and lower steering column shrouds.
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6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the
harness tie strap/clip is secured into the hole (Figure 7).
^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage.
Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert
the clip into the hole.
7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage
to the I/P wiring harness as it routes up past the fuse block (Figure 7).
8. Remove the relay access cover.
9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the
tab off of the fuse/relay/kneeblocker bracket (Figure 8).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert
the clip into the hole.
10. Install another mastic patch to the outboard end of the steel tube that routes the transmission
shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8).
11. Install the relay access cover.
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12. Install the lower steering column cover (Figure 1).
13. Connect the liftgate release switch electrical connector (Figure 1).
14. Connect the liftgate release switch electrical connector (Figure 1).
15. Tighten the lower instruments panel cover screws securely.
16. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 9).
17. Slide the cupholder out.
18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9).
19. Slide the console rearward and up to remove.
20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module
(AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
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21. Install another mastic patch over the rear corner and left edge of the Body Control Module
(BCM) (Figure 10).
22. Install the console assembly.
23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely.
Close the cupholder.
24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely.
25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Turn the ignition switch to the ON position and exit the vehicle.
27. Connect the negative battery terminal.
28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
D. Repair Passenger Airbag Wiring
IMPORTANT:
This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic
trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 11).
3. Slide the cupholder out.
4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11).
5. Slide the console rearward and up to remove.
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6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM)
(Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM)
(Figure 12).
8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness
is installed into the hole on the back side of the left center console bracket (Figure 12).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the
clip into the hole.
9. Install the console assembly.
10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely
(Figure 11). Close the cupholder.
11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely.
12. Disconnect the glove box door check straps and allow the door to open fully.
13. Working through the glove box opening, remove the four (4) screws that attach the passenger
airbag module to the I/P bracket (Figure 13).
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14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad
and lift it away from the snaps (Figure 14).
15. Hold the passenger airbag module door and raise the module from the opening. DO NOT
disconnect the airbag module electrical connectors.
16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any
chafed or cut wires should be repaired per the Wiring Repair.
17. Install a mastic patch on the edge of the passenger airbag module near the electrical
connectors (Figure 15).
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18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical
support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be
repaired per the Wiring Repair Procedure.
19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic
edge cover (Figure 16).
20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50
in-lbs (6 Nm)
21. Connect the glove box door check straps and then close the glove box door.
22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 23.
23. Install the lower steering column cover (Figure 1).
24. Connect the parking hand brake linkage (Figure 1).
25. Connect the liftgate release switch electrical connector (Figure 1).
26. Tighten the lower steering column cover screws securely.
27. Turn the ignition switch to the ON position and exit the vehicle.
28. Connect the negative battery terminal.
29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Wiring Repair Procedure
IMPORTANT:
If airbag system wiring is found chafed or damaged, the wiring should be repaired using the
procedure listed below.
^ If the plastic wire covering is chafed but the wiring strands are NOT damaged:
Tape the damaged area with high quality electrical tape.
^ If the plastic wire covering is chafed and the wiring strands are damaged:
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1. Cut the damaged wire in two.
2. Strip 1 inch of insulation from each end of the wire.
3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire.
4. Spread the strands of the wire apart on both of the exposed wire ends.
5. Push the two wire ends together until the strands of the wire are close to the insulation.
6. Twist the wires together.
7. Solder the connection together using rosin core solder.
8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint
until the tubing is tightly sealed and sealant comes out both ends of the tubing.
9. Secure the wire to the harness to prevent chafing or damage to the insulation.
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Bulletins > Recalls: > NHTSA99V113000 > May > 99 > Recall 99V113000: Inadvertent Air Bag Deployment
Air Bag: Recalls Recall 99V113000: Inadvertent Air Bag Deployment
The wiring that initiates the driver and/or passenger air bag could electrically short circuit to ground.
A short circuit to ground that exists immediately after turning the ignition key to the "ON" or
"START" position can cause the air bag(s) to inadvertently deploy.
Inadvertent air bag deployment can injure a front seat occupant.
Dealers will perform an electronic diagnostic check. Any short circuits identified in either the driver's
or passenger side air bag initiator wire circuit will be repaired.
Owner notification began August 2, 1999. Owners who take their vehicles to an authorized dealer
on an agreed upon service date and do not receive the free remedy within a reasonable time
should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Customer Interest: > 085993 > Nov > 93 > Instrument Panel - Squeak/Rattle From Right Side
Air Bag: Customer Interest Instrument Panel - Squeak/Rattle From Right Side
NO.: 08-59-93
GROUP: Electrical
DATE: Nov. 19, 1993
SUBJECT: Right Side Instrument Panel Squeak/Rattle Noise
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
SYMPTOM/CONDITION:
A squeak or rattle may be heard coming from the right side of the Instrument Panel (IP) when
driving on rough road surfaces.
DIAGNOSIS:
Visually inspect the position of the Passenger Air Bag (PAB) in the opening of the IP. If the PAB is
not centered and/or flush with the surface of the IP, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves repositioning the PAB in the IP opening.
1. Disconnect the negative battery cable.
2. Disengage the two glove box door check straps to allow for access to the four PAB attaching
screws.
3. Loosen the four black PAB attaching screws facing the glove box door until the PAB can be
easily moved in the IP opening.
4. Center the PAB in the IP opening. Use firm hand pressure to push down on the PAB door to
ensure the PAB maintains the centered position and is held flush to under-flush with the IP surface
while tightening the four PAB attaching screws to 50 In.Lbs. (5.7 N-m).
5. Reattach the two glove box door check straps.
6. Reconnect the negative battery cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-11-50-90 0.2 Hrs.
FAILURE CODE: 51 - Improperly Installed
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7306
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
Technical Service Bulletin # 818 Date: 990701
Recall - Inadvertent Airbag Deployment
July 1999
Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring
Models
1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service as determined by using the DIAL VIP System.
Subject
The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above
vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately
after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to
inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant.
Repair
A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag
system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve
replacing the clockspring). If the rear wiper motor must be replace.
Alternate Transportation
If inspection determines that clockspring and/or rear wiper motor replacement is required and the
vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by
placing the owner in a loaner vehicle.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
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Use one of the table labor operation numbers and time allowances shown.
Add the cost of the parts used plus applicable dealer allowance to your claim.
Use the labor operation number and time allowance shown if an owner requires replacement of a
rear wiper motor at some time in the future after the recall has already been completed.
Parts Return
If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be
returned for core credit as quickly as possible using the Mopar Core Return Procedure on your
DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select
Function 10.
If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the
Warranty Material Return Center.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing and material return instructions.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
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DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD818".
Owner Notification and Service Scheduling
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Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page
7314
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner notification letter is included.
Provided with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Parts Information
A. Mastic Patch
Part Number Description
55275444AB Mastic Patch
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Mastic Patches to service about 25% of those vehicles.
B. Clockspring Assembly Package
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Part Number Description
CCXR8181 Clockspring with Speed Control
CCLR8182 Clockspring without Speed Control
Each package contains a clockspring and a mastic patch.
Due to the small number of involved vehicles expected to require clockspring replacement, each
dealer will receive one clockspring for vehicles equipped with speed control. No clockspring
assemblies for vehicles without speed control will be distributed initially. Additional clockspring
packages should be ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require clockspring replacement.
C. Tie Strap/Clips and Heat Shrink Tubing
In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and
ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary.
Additional tie strap/clips and heat shrink tubing may be ordered as necessary.
D. Rear Wiper Motor Assembly
Part Number Description
R4673326 Remanufactured Rear Wiper Motor Assembly
OR
04673326 New Rear Wiper Motor Assembly
Due to the small number of involved vehicles expected to require rear wiper motor replacement, no
wiper motors will be distributed initially. Wiper motors should be ordered only after inspection
determines that replacement is required. Very few vehicles are expected to require rear wiper
motor replacement.
A. Install Mastic Patch & Check For Airbag System
Diagnostic Trouble Codes (DTC's):
1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off.
2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1).
3. Disconnect the liftgate release switch electrical connector (Figure 1).
4. Disconnect the parking hand brake linkage.
5. Set the lower steering column cover aside.
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6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure
2).
7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect
the DRB III to the underdash diagnostic connector (blue connector to the right of the steering
column) and power it up.
8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen.
9. Turn the ignition key tot he "ON" position.
10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN
MENU Screen.
12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen.
14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen.
15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen.
16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen.
17. Record all active DTC's for future reference.
18. Press the PAGE BACK key to return to the DTC TYPE Screen.
19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen.
20. Record all stored DTC's for future reference.
21. Press the PAGE BACK key to continue.
22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present).
23. Press the PAGE BACK key to continue.
24. Turn the ignition key off and disconnect the DRB III.
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25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the
table. If no airbag system DTC's exist, continue with Step 26.
NOTE:
Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any
airbag system diagnostic trouble codes other than those listed above.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Return the vehicle to the customer. No further action is necessary.
B. Replace Rear Wiper Motor
IMPORTANT:
This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the liftgate wiper arm assembly.
3. Open and raise the liftgate.
4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3).
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5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws
(Figure 3).
6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel
screws (Figure 3).
7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3).
8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and
remove the screws (Figure 3).
9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel
(Figure 3).
10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel
from the liftgate.
11. Disconnect the wiper motor electrical connector (Figure 4).
12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor
and bracket assembly from the liftgate and set it aside.
13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate.
Torque the five (5) attaching screws to 35 in-lbs (4 Nm).
14. Connect the wiper motor electrical connector.
15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter
of the panel.
16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3).
CAUTION:
DO NOT over tighten screws as this could damage the trim panel or strip the screws.
17. Install the two (2) screws located in the speaker grille openings (Figure 3).
18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3).
19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3).
20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs.
21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp
assemblies.
22. Close the liftgate.
23. Install the liftgate wiper arm assembly.
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24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse
(Fuse # 13) with a new 20 amp fuse (Figure 5).
25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be
repaired, continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Turn the ignition switch to the ON position and exit the vehicle.
31. Connect the negative battery terminal.
32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
C. Repair Driver Airbag Wiring and.or Replace Clockspring
IMPORTANT:
This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble
code.
1. Place the steering wheel in the straight ahead position.
2. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
3. Remove the upper and lower steering column shrouds.
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4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure
6).
^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5.
^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged,
repair the clockspring wires by taping the damaged area with high quality electrical tape and tie
strap as shown in Figure 6.
^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged,
replace the clockspring assembly as follows:
a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel,
disconnect the airbag module electrical connector and then remove the airbag module from the
steering wheel and set it aside (inflator side down/face up for safety).
b. Disconnect the speed control switch connector (if equipped).
c. Disconnect the horn connector.
d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool
C-3428B), remove the steering wheel.
e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring
pigtail from the steering column.
f. Disconnect the clockspring wiring connector from the back of the clockspring.
g. Unclip the clockspring assembly locating fingers from the steering column and then remove and
discard the clockspring.
h. Snap the new clockspring onto the steering column.
i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring
harness that connects to the ignition switch is between the pigtail and the steering column. Secure
the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6).
j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail
to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA)
(Figure 6).
k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm).
l. Connect the horn connector.
m. Connect the speed control switch connector (if equipped).
n. Connect the airbag module electrical connector and install the airbag module onto the steering
wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm).
5. Install the upper and lower steering column shrouds.
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6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the
harness tie strap/clip is secured into the hole (Figure 7).
^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage.
Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert
the clip into the hole.
7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage
to the I/P wiring harness as it routes up past the fuse block (Figure 7).
8. Remove the relay access cover.
9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the
tab off of the fuse/relay/kneeblocker bracket (Figure 8).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert
the clip into the hole.
10. Install another mastic patch to the outboard end of the steel tube that routes the transmission
shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8).
11. Install the relay access cover.
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12. Install the lower steering column cover (Figure 1).
13. Connect the liftgate release switch electrical connector (Figure 1).
14. Connect the liftgate release switch electrical connector (Figure 1).
15. Tighten the lower instruments panel cover screws securely.
16. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 9).
17. Slide the cupholder out.
18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9).
19. Slide the console rearward and up to remove.
20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module
(AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
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21. Install another mastic patch over the rear corner and left edge of the Body Control Module
(BCM) (Figure 10).
22. Install the console assembly.
23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely.
Close the cupholder.
24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely.
25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Turn the ignition switch to the ON position and exit the vehicle.
27. Connect the negative battery terminal.
28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
D. Repair Passenger Airbag Wiring
IMPORTANT:
This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic
trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 11).
3. Slide the cupholder out.
4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11).
5. Slide the console rearward and up to remove.
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6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM)
(Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM)
(Figure 12).
8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness
is installed into the hole on the back side of the left center console bracket (Figure 12).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the
clip into the hole.
9. Install the console assembly.
10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely
(Figure 11). Close the cupholder.
11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely.
12. Disconnect the glove box door check straps and allow the door to open fully.
13. Working through the glove box opening, remove the four (4) screws that attach the passenger
airbag module to the I/P bracket (Figure 13).
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14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad
and lift it away from the snaps (Figure 14).
15. Hold the passenger airbag module door and raise the module from the opening. DO NOT
disconnect the airbag module electrical connectors.
16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any
chafed or cut wires should be repaired per the Wiring Repair.
17. Install a mastic patch on the edge of the passenger airbag module near the electrical
connectors (Figure 15).
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18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical
support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be
repaired per the Wiring Repair Procedure.
19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic
edge cover (Figure 16).
20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50
in-lbs (6 Nm)
21. Connect the glove box door check straps and then close the glove box door.
22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 23.
23. Install the lower steering column cover (Figure 1).
24. Connect the parking hand brake linkage (Figure 1).
25. Connect the liftgate release switch electrical connector (Figure 1).
26. Tighten the lower steering column cover screws securely.
27. Turn the ignition switch to the ON position and exit the vehicle.
28. Connect the negative battery terminal.
29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Wiring Repair Procedure
IMPORTANT:
If airbag system wiring is found chafed or damaged, the wiring should be repaired using the
procedure listed below.
^ If the plastic wire covering is chafed but the wiring strands are NOT damaged:
Tape the damaged area with high quality electrical tape.
^ If the plastic wire covering is chafed and the wiring strands are damaged:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page
7327
1. Cut the damaged wire in two.
2. Strip 1 inch of insulation from each end of the wire.
3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire.
4. Spread the strands of the wire apart on both of the exposed wire ends.
5. Push the two wire ends together until the strands of the wire are close to the insulation.
6. Twist the wires together.
7. Solder the connection together using rosin core solder.
8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint
until the tubing is tightly sealed and sealant comes out both ends of the tubing.
9. Secure the wire to the harness to prevent chafing or damage to the insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Bag: > NHTSA99V113000 > May > 99 > Recall 99V113000: Inadvertent Air
Bag Deployment
Air Bag: All Technical Service Bulletins Recall 99V113000: Inadvertent Air Bag Deployment
The wiring that initiates the driver and/or passenger air bag could electrically short circuit to ground.
A short circuit to ground that exists immediately after turning the ignition key to the "ON" or
"START" position can cause the air bag(s) to inadvertently deploy.
Inadvertent air bag deployment can injure a front seat occupant.
Dealers will perform an electronic diagnostic check. Any short circuits identified in either the driver's
or passenger side air bag initiator wire circuit will be repaired.
Owner notification began August 2, 1999. Owners who take their vehicles to an authorized dealer
on an agreed upon service date and do not receive the free remedy within a reasonable time
should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Bag: > 085993 > Nov > 93 > Instrument Panel - Squeak/Rattle From Right
Side
Air Bag: All Technical Service Bulletins Instrument Panel - Squeak/Rattle From Right Side
NO.: 08-59-93
GROUP: Electrical
DATE: Nov. 19, 1993
SUBJECT: Right Side Instrument Panel Squeak/Rattle Noise
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
SYMPTOM/CONDITION:
A squeak or rattle may be heard coming from the right side of the Instrument Panel (IP) when
driving on rough road surfaces.
DIAGNOSIS:
Visually inspect the position of the Passenger Air Bag (PAB) in the opening of the IP. If the PAB is
not centered and/or flush with the surface of the IP, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves repositioning the PAB in the IP opening.
1. Disconnect the negative battery cable.
2. Disengage the two glove box door check straps to allow for access to the four PAB attaching
screws.
3. Loosen the four black PAB attaching screws facing the glove box door until the PAB can be
easily moved in the IP opening.
4. Center the PAB in the IP opening. Use firm hand pressure to push down on the PAB door to
ensure the PAB maintains the centered position and is held flush to under-flush with the IP surface
while tightening the four PAB attaching screws to 50 In.Lbs. (5.7 N-m).
5. Reattach the two glove box door check straps.
6. Reconnect the negative battery cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-11-50-90 0.2 Hrs.
FAILURE CODE: 51 - Improperly Installed
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7341
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 085993 > Nov > 93 > Instrument Panel - Squeak/Rattle From Right Side
Air Bag: All Technical Service Bulletins Instrument Panel - Squeak/Rattle From Right Side
NO.: 08-59-93
GROUP: Electrical
DATE: Nov. 19, 1993
SUBJECT: Right Side Instrument Panel Squeak/Rattle Noise
MODELS:
1994 (AS) Caravan/Voyager/Town & Country
SYMPTOM/CONDITION:
A squeak or rattle may be heard coming from the right side of the Instrument Panel (IP) when
driving on rough road surfaces.
DIAGNOSIS:
Visually inspect the position of the Passenger Air Bag (PAB) in the opening of the IP. If the PAB is
not centered and/or flush with the surface of the IP, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves repositioning the PAB in the IP opening.
1. Disconnect the negative battery cable.
2. Disengage the two glove box door check straps to allow for access to the four PAB attaching
screws.
3. Loosen the four black PAB attaching screws facing the glove box door until the PAB can be
easily moved in the IP opening.
4. Center the PAB in the IP opening. Use firm hand pressure to push down on the PAB door to
ensure the PAB maintains the centered position and is held flush to under-flush with the IP surface
while tightening the four PAB attaching screws to 50 In.Lbs. (5.7 N-m).
5. Reattach the two glove box door check straps.
6. Reconnect the negative battery cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-11-50-90 0.2 Hrs.
FAILURE CODE: 51 - Improperly Installed
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7351
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
Technical Service Bulletin # 818 Date: 990701
Recall - Inadvertent Airbag Deployment
July 1999
Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring
Models
1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service as determined by using the DIAL VIP System.
Subject
The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above
vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately
after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to
inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant.
Repair
A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag
system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve
replacing the clockspring). If the rear wiper motor must be replace.
Alternate Transportation
If inspection determines that clockspring and/or rear wiper motor replacement is required and the
vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by
placing the owner in a loaner vehicle.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7356
Use one of the table labor operation numbers and time allowances shown.
Add the cost of the parts used plus applicable dealer allowance to your claim.
Use the labor operation number and time allowance shown if an owner requires replacement of a
rear wiper motor at some time in the future after the recall has already been completed.
Parts Return
If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be
returned for core credit as quickly as possible using the Mopar Core Return Procedure on your
DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select
Function 10.
If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the
Warranty Material Return Center.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing and material return instructions.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7357
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD818".
Owner Notification and Service Scheduling
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Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7358
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7359
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner notification letter is included.
Provided with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Parts Information
A. Mastic Patch
Part Number Description
55275444AB Mastic Patch
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Mastic Patches to service about 25% of those vehicles.
B. Clockspring Assembly Package
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7360
Part Number Description
CCXR8181 Clockspring with Speed Control
CCLR8182 Clockspring without Speed Control
Each package contains a clockspring and a mastic patch.
Due to the small number of involved vehicles expected to require clockspring replacement, each
dealer will receive one clockspring for vehicles equipped with speed control. No clockspring
assemblies for vehicles without speed control will be distributed initially. Additional clockspring
packages should be ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require clockspring replacement.
C. Tie Strap/Clips and Heat Shrink Tubing
In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and
ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary.
Additional tie strap/clips and heat shrink tubing may be ordered as necessary.
D. Rear Wiper Motor Assembly
Part Number Description
R4673326 Remanufactured Rear Wiper Motor Assembly
OR
04673326 New Rear Wiper Motor Assembly
Due to the small number of involved vehicles expected to require rear wiper motor replacement, no
wiper motors will be distributed initially. Wiper motors should be ordered only after inspection
determines that replacement is required. Very few vehicles are expected to require rear wiper
motor replacement.
A. Install Mastic Patch & Check For Airbag System
Diagnostic Trouble Codes (DTC's):
1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off.
2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1).
3. Disconnect the liftgate release switch electrical connector (Figure 1).
4. Disconnect the parking hand brake linkage.
5. Set the lower steering column cover aside.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7361
6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure
2).
7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect
the DRB III to the underdash diagnostic connector (blue connector to the right of the steering
column) and power it up.
8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen.
9. Turn the ignition key tot he "ON" position.
10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN
MENU Screen.
12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen.
14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen.
15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen.
16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen.
17. Record all active DTC's for future reference.
18. Press the PAGE BACK key to return to the DTC TYPE Screen.
19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen.
20. Record all stored DTC's for future reference.
21. Press the PAGE BACK key to continue.
22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present).
23. Press the PAGE BACK key to continue.
24. Turn the ignition key off and disconnect the DRB III.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7362
25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the
table. If no airbag system DTC's exist, continue with Step 26.
NOTE:
Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any
airbag system diagnostic trouble codes other than those listed above.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Return the vehicle to the customer. No further action is necessary.
B. Replace Rear Wiper Motor
IMPORTANT:
This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the liftgate wiper arm assembly.
3. Open and raise the liftgate.
4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3).
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7363
5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws
(Figure 3).
6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel
screws (Figure 3).
7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3).
8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and
remove the screws (Figure 3).
9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel
(Figure 3).
10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel
from the liftgate.
11. Disconnect the wiper motor electrical connector (Figure 4).
12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor
and bracket assembly from the liftgate and set it aside.
13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate.
Torque the five (5) attaching screws to 35 in-lbs (4 Nm).
14. Connect the wiper motor electrical connector.
15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter
of the panel.
16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3).
CAUTION:
DO NOT over tighten screws as this could damage the trim panel or strip the screws.
17. Install the two (2) screws located in the speaker grille openings (Figure 3).
18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3).
19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3).
20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs.
21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp
assemblies.
22. Close the liftgate.
23. Install the liftgate wiper arm assembly.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7364
24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse
(Fuse # 13) with a new 20 amp fuse (Figure 5).
25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be
repaired, continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Turn the ignition switch to the ON position and exit the vehicle.
31. Connect the negative battery terminal.
32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
C. Repair Driver Airbag Wiring and.or Replace Clockspring
IMPORTANT:
This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble
code.
1. Place the steering wheel in the straight ahead position.
2. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
3. Remove the upper and lower steering column shrouds.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7365
4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure
6).
^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5.
^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged,
repair the clockspring wires by taping the damaged area with high quality electrical tape and tie
strap as shown in Figure 6.
^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged,
replace the clockspring assembly as follows:
a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel,
disconnect the airbag module electrical connector and then remove the airbag module from the
steering wheel and set it aside (inflator side down/face up for safety).
b. Disconnect the speed control switch connector (if equipped).
c. Disconnect the horn connector.
d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool
C-3428B), remove the steering wheel.
e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring
pigtail from the steering column.
f. Disconnect the clockspring wiring connector from the back of the clockspring.
g. Unclip the clockspring assembly locating fingers from the steering column and then remove and
discard the clockspring.
h. Snap the new clockspring onto the steering column.
i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring
harness that connects to the ignition switch is between the pigtail and the steering column. Secure
the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6).
j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail
to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA)
(Figure 6).
k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm).
l. Connect the horn connector.
m. Connect the speed control switch connector (if equipped).
n. Connect the airbag module electrical connector and install the airbag module onto the steering
wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm).
5. Install the upper and lower steering column shrouds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7366
6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the
harness tie strap/clip is secured into the hole (Figure 7).
^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage.
Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert
the clip into the hole.
7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage
to the I/P wiring harness as it routes up past the fuse block (Figure 7).
8. Remove the relay access cover.
9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the
tab off of the fuse/relay/kneeblocker bracket (Figure 8).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert
the clip into the hole.
10. Install another mastic patch to the outboard end of the steel tube that routes the transmission
shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8).
11. Install the relay access cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7367
12. Install the lower steering column cover (Figure 1).
13. Connect the liftgate release switch electrical connector (Figure 1).
14. Connect the liftgate release switch electrical connector (Figure 1).
15. Tighten the lower instruments panel cover screws securely.
16. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 9).
17. Slide the cupholder out.
18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9).
19. Slide the console rearward and up to remove.
20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module
(AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7368
21. Install another mastic patch over the rear corner and left edge of the Body Control Module
(BCM) (Figure 10).
22. Install the console assembly.
23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely.
Close the cupholder.
24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely.
25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Turn the ignition switch to the ON position and exit the vehicle.
27. Connect the negative battery terminal.
28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
D. Repair Passenger Airbag Wiring
IMPORTANT:
This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic
trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 11).
3. Slide the cupholder out.
4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11).
5. Slide the console rearward and up to remove.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7369
6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM)
(Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM)
(Figure 12).
8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness
is installed into the hole on the back side of the left center console bracket (Figure 12).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the
clip into the hole.
9. Install the console assembly.
10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely
(Figure 11). Close the cupholder.
11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely.
12. Disconnect the glove box door check straps and allow the door to open fully.
13. Working through the glove box opening, remove the four (4) screws that attach the passenger
airbag module to the I/P bracket (Figure 13).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7370
14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad
and lift it away from the snaps (Figure 14).
15. Hold the passenger airbag module door and raise the module from the opening. DO NOT
disconnect the airbag module electrical connectors.
16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any
chafed or cut wires should be repaired per the Wiring Repair.
17. Install a mastic patch on the edge of the passenger airbag module near the electrical
connectors (Figure 15).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7371
18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical
support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be
repaired per the Wiring Repair Procedure.
19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic
edge cover (Figure 16).
20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50
in-lbs (6 Nm)
21. Connect the glove box door check straps and then close the glove box door.
22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 23.
23. Install the lower steering column cover (Figure 1).
24. Connect the parking hand brake linkage (Figure 1).
25. Connect the liftgate release switch electrical connector (Figure 1).
26. Tighten the lower steering column cover screws securely.
27. Turn the ignition switch to the ON position and exit the vehicle.
28. Connect the negative battery terminal.
29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Wiring Repair Procedure
IMPORTANT:
If airbag system wiring is found chafed or damaged, the wiring should be repaired using the
procedure listed below.
^ If the plastic wire covering is chafed but the wiring strands are NOT damaged:
Tape the damaged area with high quality electrical tape.
^ If the plastic wire covering is chafed and the wiring strands are damaged:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7372
1. Cut the damaged wire in two.
2. Strip 1 inch of insulation from each end of the wire.
3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire.
4. Spread the strands of the wire apart on both of the exposed wire ends.
5. Push the two wire ends together until the strands of the wire are close to the insulation.
6. Twist the wires together.
7. Solder the connection together using rosin core solder.
8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint
until the tubing is tightly sealed and sealant comes out both ends of the tubing.
9. Secure the wire to the harness to prevent chafing or damage to the insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Air Bag: > NHTSA99V113000 > May > 99 > Recall 99V113000: Inadvertent Air
Bag Deployment
Air Bag: All Technical Service Bulletins Recall 99V113000: Inadvertent Air Bag Deployment
The wiring that initiates the driver and/or passenger air bag could electrically short circuit to ground.
A short circuit to ground that exists immediately after turning the ignition key to the "ON" or
"START" position can cause the air bag(s) to inadvertently deploy.
Inadvertent air bag deployment can injure a front seat occupant.
Dealers will perform an electronic diagnostic check. Any short circuits identified in either the driver's
or passenger side air bag initiator wire circuit will be repaired.
Owner notification began August 2, 1999. Owners who take their vehicles to an authorized dealer
on an agreed upon service date and do not receive the free remedy within a reasonable time
should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Component Locations
Dash And Console Mounted Component Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Component Locations > Page 7379
Air Bag Module And Connector Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service
Precautions > Customer Safety Information
Air Bag: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service
Precautions > Customer Safety Information > Page 7382
Air Bag: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service
Precautions > Page 7383
Air Bag: Description and Operation
DRIVER SIDE
The driver side airbag module, located in the center of the steering wheel, contains the airbag
cushion and its supporting components. The airbag cushion and inflator are attached to and sealed by the airbag module housing.
The driver side inflator is mounted on the back of the module housing.
When supplied with the proper electrical signal the inflator produces a gas and discharges it
directly into the cushion. A decorative, protective cover is fitted on the front of the driver airbag
module housing.
PASSENGER SIDE
This bag assembly utilizes a canister of a compressed, inert gas to inflate the bag, instead of the
sodium azide charge used previously.
The pressure of the canister is monitored by a non-serviceable pressure switch, which is built into
the canister. The pressure switch is wired to and monitored by the air bag control module.
When supplied with the proper electrical signal the inflator produces a gas and discharges it
directly into the cushion. A decorative, protective cover is fitted over the airbag module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Testing and
Inspection > Component Tests and General Diagnostics
Air Bag: Component Tests and General Diagnostics
GENERAL INSPECTION
A visual inspection consists of physically looking for possible cause of a malfunction. A careful and
thorough visual inspection of components may quickly identify malfunction cause and eliminate
need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with
diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are
properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag
warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go
out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case
and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for
damage and terminals for deformities. 7. Remove air bag module as outlined under Component
Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified
tester. 9. Check air bag pad cover for dents, cracks or deformities.
10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for
damage, terminals for deformities and harness for binds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Testing and
Inspection > Component Tests and General Diagnostics > Page 7386
Air Bag: Scan Tool Testing and Procedures
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Air Bag Module Disposal Procedures
Air Bag: Service and Repair Air Bag Module Disposal Procedures
See: AIR BAG MODULE DISPOSAL
After deployment, air bag module should be placed in a plastic bag and disposed of in same
manner as any other scrap parts, except that following points should be carefully noted during
disposal. 1. When handling deployed air bag assembly, face shield and rubber gloves should be
worn. 2. There may be material adhered to air bag module that could irritate eyes and/or skin. If
any irritation develops, seek medical attention. Note
following: a. If sinus or throat irritation is encountered during air bag removal, exit vehicle and
breath fresh air. b. If material does come in contact with eyes and/or skin, immediately rinse
affected area with a large amount of cool, clean water. c. If sinus, throat, skin or any other type of
irritation continues, consult a physician.
3. After handling a deployed air bag assembly, wash hands and rinse thoroughly with water. 4.
Inflator will be quite hot immediately after deployment, wait 30 minutes to allow air bag to cool. 5.
Do not put water or oil on air bag after deployment. 6. Put deployed air bag in a hermetically sealed
container and discard it. 7. Use a vacuum cleaner to remove any residual powder from vehicle
interior as follows:
a. Work from outside to center of vehicle. b. Vacuum A/C, vent, defroster and heater ducts. c. Run
blower motor on low speed and vacuum any powder expelled from plenum. d. It may be necessary
to vacuum interior of vehicle a second time to ensure all powder is recovered.
8. An air bag that has been deployed should be removed as outlined under Driver Air Bag
Assembly, Replace
See: Driver Side Airbag Module Replacement
or Passenger Air Bag Assembly, Replace.
See: Passenger Side Airbag Module Replacement
9. Prior to removing a deployed air bag assembly, place tape over air bag exhaust vents.
10. Before disposing of a vehicle equipped with air bag(s), or prior to disposing of air bag module,
module must be deployed as follows:
a. If vehicle is to be scrapped, deploy air bag(s) inside vehicle. b. If vehicle is to continue in service,
air bags must be removed and deployed outside vehicle.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Air Bag Module Disposal Procedures > Page 7389
Air Bag: Service and Repair Driver Side Airbag Module Replacement
Fig. 1 Driver Air Bag Module Replacement
DRIVER AIR BAG MODULE, REPLACE
1. Disarm air bag as outlined under Air Bag System Disarming and Arming.
See: Air Bag(s) Arming and Disarming/Service and Repair
2. Remove air bag module nuts for steering wheel. 3. Lift module and disconnect electrical
connector. 4. Remove module. 5. Reverse procedure to install and tighten nuts to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Air Bag Module Disposal Procedures > Page 7390
Air Bag: Service and Repair Passenger Side Airbag Module Replacement
PASSENGER AIR BAG MODULE, REPLACE, CARAVAN, TOWN & COUNTRY & VOYAGER
1. Disarm air bag as outlined under Air Bag System Disarming and Arming.
See: Air Bag(s) Arming and Disarming/Service and Repair
2. If air bag module has deployed, roll or fold air bag toward instrument panel, then close door over
air bag and tape closed. 3. Disconnect glove compartment door and allow door to fully open. 4.
Remove air bag module mounting screws. 5. Pry module up with large flat tipped screws driver to
unsnap door from trim pad, then lift away from snaps. 6. Hold on to door, lift module from opening
and rest module on trim pad. 7. Disconnect electrical connectors and remove module. 8. Reverse
procedure to install and tighten screws to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Locations
Air Bag Control Module And Body Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector
Air Bag Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page
7396
Air Bag Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page
7397
Airbag System Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information
Supplemental Restraint System (SRS) Control Module: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 7400
Supplemental Restraint System (SRS) Control Module: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 7401
Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings
CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF"
and the battery is disconnected. Failure to do so could damage the module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Service Precautions > Page 7402
Supplemental Restraint System (SRS) Control Module: Description and Operation
OPERATION
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the air bags. The total time between determining to deploy and deflation of the air bag is 1/10th of a
second.
SELF DIAGNOSTIC FUNCTIONS
Whenever the ignition key is turned to the "RUN" or "START" position, the air bag control module
(ACM) performs a lamp check by turning the AIR BAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM
has checked the system and found it to be free of discernible malfunctions. The air bag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the air bag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The
ACM provides diagnostic information about the air bag system to the technician through the DRB
via the CCD bus.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General
Diagnostics
Supplemental Restraint System (SRS) Control Module: Component Tests and General Diagnostics
GENERAL INSPECTION
A visual inspection consists of physically looking for possible cause of a malfunction. A careful and
thorough visual inspection of components may quickly identify malfunction cause and eliminate
need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with
diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are
properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag
warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go
out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case
and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for
damage and terminals for deformities. 7. Remove air bag module as outlined under Component
Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified
tester. 9. Check air bag pad cover for dents, cracks or deformities.
10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for
damage, terminals for deformities and harness for binds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General
Diagnostics > Page 7405
Supplemental Restraint System (SRS) Control Module: Scan Tool Testing and Procedures
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module
<--> [Air Bag Control Module] > Component Information > Testing and Inspection > Page 7406
Supplemental Restraint System (SRS) Control Module: Service and Repair
AIR BAG CONTROL (ACM), REPLACE
1. Disarm air bag system as outlined under Air Bag System Disarming and Arming.
See: Air Bag(s) Arming and Disarming/Service and Repair
2. Remove screws attaching lower console to instrument panel support bracket. 3. Remove upper
console attaching screws behind cup holder, then slide console to rear and up to remove. 4.
Disconnect ACM wiring and remove module, then remove ACM mounting screws. 5. Reverse
procedure to install and tighten screws to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7411
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7412
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7413
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7414
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7415
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7416
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
Technical Service Bulletin # 818 Date: 990701
Recall - Inadvertent Airbag Deployment
July 1999
Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring
Models
1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service as determined by using the DIAL VIP System.
Subject
The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above
vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately
after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to
inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant.
Repair
A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag
system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve
replacing the clockspring). If the rear wiper motor must be replace.
Alternate Transportation
If inspection determines that clockspring and/or rear wiper motor replacement is required and the
vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by
placing the owner in a loaner vehicle.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7425
Use one of the table labor operation numbers and time allowances shown.
Add the cost of the parts used plus applicable dealer allowance to your claim.
Use the labor operation number and time allowance shown if an owner requires replacement of a
rear wiper motor at some time in the future after the recall has already been completed.
Parts Return
If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be
returned for core credit as quickly as possible using the Mopar Core Return Procedure on your
DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select
Function 10.
If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the
Warranty Material Return Center.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing and material return instructions.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7426
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD818".
Owner Notification and Service Scheduling
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7427
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7428
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner notification letter is included.
Provided with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Parts Information
A. Mastic Patch
Part Number Description
55275444AB Mastic Patch
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Mastic Patches to service about 25% of those vehicles.
B. Clockspring Assembly Package
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7429
Part Number Description
CCXR8181 Clockspring with Speed Control
CCLR8182 Clockspring without Speed Control
Each package contains a clockspring and a mastic patch.
Due to the small number of involved vehicles expected to require clockspring replacement, each
dealer will receive one clockspring for vehicles equipped with speed control. No clockspring
assemblies for vehicles without speed control will be distributed initially. Additional clockspring
packages should be ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require clockspring replacement.
C. Tie Strap/Clips and Heat Shrink Tubing
In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and
ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary.
Additional tie strap/clips and heat shrink tubing may be ordered as necessary.
D. Rear Wiper Motor Assembly
Part Number Description
R4673326 Remanufactured Rear Wiper Motor Assembly
OR
04673326 New Rear Wiper Motor Assembly
Due to the small number of involved vehicles expected to require rear wiper motor replacement, no
wiper motors will be distributed initially. Wiper motors should be ordered only after inspection
determines that replacement is required. Very few vehicles are expected to require rear wiper
motor replacement.
A. Install Mastic Patch & Check For Airbag System
Diagnostic Trouble Codes (DTC's):
1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off.
2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1).
3. Disconnect the liftgate release switch electrical connector (Figure 1).
4. Disconnect the parking hand brake linkage.
5. Set the lower steering column cover aside.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7430
6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure
2).
7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect
the DRB III to the underdash diagnostic connector (blue connector to the right of the steering
column) and power it up.
8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen.
9. Turn the ignition key tot he "ON" position.
10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN
MENU Screen.
12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen.
14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen.
15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen.
16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen.
17. Record all active DTC's for future reference.
18. Press the PAGE BACK key to return to the DTC TYPE Screen.
19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen.
20. Record all stored DTC's for future reference.
21. Press the PAGE BACK key to continue.
22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present).
23. Press the PAGE BACK key to continue.
24. Turn the ignition key off and disconnect the DRB III.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7431
25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the
table. If no airbag system DTC's exist, continue with Step 26.
NOTE:
Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any
airbag system diagnostic trouble codes other than those listed above.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Return the vehicle to the customer. No further action is necessary.
B. Replace Rear Wiper Motor
IMPORTANT:
This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the liftgate wiper arm assembly.
3. Open and raise the liftgate.
4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7432
5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws
(Figure 3).
6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel
screws (Figure 3).
7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3).
8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and
remove the screws (Figure 3).
9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel
(Figure 3).
10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel
from the liftgate.
11. Disconnect the wiper motor electrical connector (Figure 4).
12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor
and bracket assembly from the liftgate and set it aside.
13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate.
Torque the five (5) attaching screws to 35 in-lbs (4 Nm).
14. Connect the wiper motor electrical connector.
15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter
of the panel.
16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3).
CAUTION:
DO NOT over tighten screws as this could damage the trim panel or strip the screws.
17. Install the two (2) screws located in the speaker grille openings (Figure 3).
18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3).
19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3).
20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs.
21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp
assemblies.
22. Close the liftgate.
23. Install the liftgate wiper arm assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7433
24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse
(Fuse # 13) with a new 20 amp fuse (Figure 5).
25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be
repaired, continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Turn the ignition switch to the ON position and exit the vehicle.
31. Connect the negative battery terminal.
32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
C. Repair Driver Airbag Wiring and.or Replace Clockspring
IMPORTANT:
This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble
code.
1. Place the steering wheel in the straight ahead position.
2. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
3. Remove the upper and lower steering column shrouds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7434
4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure
6).
^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5.
^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged,
repair the clockspring wires by taping the damaged area with high quality electrical tape and tie
strap as shown in Figure 6.
^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged,
replace the clockspring assembly as follows:
a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel,
disconnect the airbag module electrical connector and then remove the airbag module from the
steering wheel and set it aside (inflator side down/face up for safety).
b. Disconnect the speed control switch connector (if equipped).
c. Disconnect the horn connector.
d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool
C-3428B), remove the steering wheel.
e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring
pigtail from the steering column.
f. Disconnect the clockspring wiring connector from the back of the clockspring.
g. Unclip the clockspring assembly locating fingers from the steering column and then remove and
discard the clockspring.
h. Snap the new clockspring onto the steering column.
i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring
harness that connects to the ignition switch is between the pigtail and the steering column. Secure
the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6).
j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail
to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA)
(Figure 6).
k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm).
l. Connect the horn connector.
m. Connect the speed control switch connector (if equipped).
n. Connect the airbag module electrical connector and install the airbag module onto the steering
wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm).
5. Install the upper and lower steering column shrouds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7435
6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the
harness tie strap/clip is secured into the hole (Figure 7).
^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage.
Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert
the clip into the hole.
7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage
to the I/P wiring harness as it routes up past the fuse block (Figure 7).
8. Remove the relay access cover.
9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the
tab off of the fuse/relay/kneeblocker bracket (Figure 8).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert
the clip into the hole.
10. Install another mastic patch to the outboard end of the steel tube that routes the transmission
shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8).
11. Install the relay access cover.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7436
12. Install the lower steering column cover (Figure 1).
13. Connect the liftgate release switch electrical connector (Figure 1).
14. Connect the liftgate release switch electrical connector (Figure 1).
15. Tighten the lower instruments panel cover screws securely.
16. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 9).
17. Slide the cupholder out.
18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9).
19. Slide the console rearward and up to remove.
20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module
(AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
> Page 7437
21. Install another mastic patch over the rear corner and left edge of the Body Control Module
(BCM) (Figure 10).
22. Install the console assembly.
23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely.
Close the cupholder.
24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely.
25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Turn the ignition switch to the ON position and exit the vehicle.
27. Connect the negative battery terminal.
28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
D. Repair Passenger Airbag Wiring
IMPORTANT:
This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic
trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 11).
3. Slide the cupholder out.
4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11).
5. Slide the console rearward and up to remove.
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> Page 7438
6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM)
(Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM)
(Figure 12).
8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness
is installed into the hole on the back side of the left center console bracket (Figure 12).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the
clip into the hole.
9. Install the console assembly.
10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely
(Figure 11). Close the cupholder.
11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely.
12. Disconnect the glove box door check straps and allow the door to open fully.
13. Working through the glove box opening, remove the four (4) screws that attach the passenger
airbag module to the I/P bracket (Figure 13).
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> Page 7439
14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad
and lift it away from the snaps (Figure 14).
15. Hold the passenger airbag module door and raise the module from the opening. DO NOT
disconnect the airbag module electrical connectors.
16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any
chafed or cut wires should be repaired per the Wiring Repair.
17. Install a mastic patch on the edge of the passenger airbag module near the electrical
connectors (Figure 15).
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> Page 7440
18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical
support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be
repaired per the Wiring Repair Procedure.
19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic
edge cover (Figure 16).
20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50
in-lbs (6 Nm)
21. Connect the glove box door check straps and then close the glove box door.
22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 23.
23. Install the lower steering column cover (Figure 1).
24. Connect the parking hand brake linkage (Figure 1).
25. Connect the liftgate release switch electrical connector (Figure 1).
26. Tighten the lower steering column cover screws securely.
27. Turn the ignition switch to the ON position and exit the vehicle.
28. Connect the negative battery terminal.
29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Wiring Repair Procedure
IMPORTANT:
If airbag system wiring is found chafed or damaged, the wiring should be repaired using the
procedure listed below.
^ If the plastic wire covering is chafed but the wiring strands are NOT damaged:
Tape the damaged area with high quality electrical tape.
^ If the plastic wire covering is chafed and the wiring strands are damaged:
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> Page 7441
1. Cut the damaged wire in two.
2. Strip 1 inch of insulation from each end of the wire.
3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire.
4. Spread the strands of the wire apart on both of the exposed wire ends.
5. Push the two wire ends together until the strands of the wire are close to the insulation.
6. Twist the wires together.
7. Solder the connection together using rosin core solder.
8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint
until the tubing is tightly sealed and sealant comes out both ends of the tubing.
9. Secure the wire to the harness to prevent chafing or damage to the insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
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Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7447
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
Technical Service Bulletin # 818 Date: 990701
Recall - Inadvertent Airbag Deployment
July 1999
Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring
Models
1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service as determined by using the DIAL VIP System.
Subject
The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above
vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately
after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to
inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant.
Repair
A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag
system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve
replacing the clockspring). If the rear wiper motor must be replace.
Alternate Transportation
If inspection determines that clockspring and/or rear wiper motor replacement is required and the
vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by
placing the owner in a loaner vehicle.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
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Use one of the table labor operation numbers and time allowances shown.
Add the cost of the parts used plus applicable dealer allowance to your claim.
Use the labor operation number and time allowance shown if an owner requires replacement of a
rear wiper motor at some time in the future after the recall has already been completed.
Parts Return
If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be
returned for core credit as quickly as possible using the Mopar Core Return Procedure on your
DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select
Function 10.
If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the
Warranty Material Return Center.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing and material return instructions.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
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DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD818".
Owner Notification and Service Scheduling
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7455
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner notification letter is included.
Provided with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Parts Information
A. Mastic Patch
Part Number Description
55275444AB Mastic Patch
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Mastic Patches to service about 25% of those vehicles.
B. Clockspring Assembly Package
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7456
Part Number Description
CCXR8181 Clockspring with Speed Control
CCLR8182 Clockspring without Speed Control
Each package contains a clockspring and a mastic patch.
Due to the small number of involved vehicles expected to require clockspring replacement, each
dealer will receive one clockspring for vehicles equipped with speed control. No clockspring
assemblies for vehicles without speed control will be distributed initially. Additional clockspring
packages should be ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require clockspring replacement.
C. Tie Strap/Clips and Heat Shrink Tubing
In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and
ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary.
Additional tie strap/clips and heat shrink tubing may be ordered as necessary.
D. Rear Wiper Motor Assembly
Part Number Description
R4673326 Remanufactured Rear Wiper Motor Assembly
OR
04673326 New Rear Wiper Motor Assembly
Due to the small number of involved vehicles expected to require rear wiper motor replacement, no
wiper motors will be distributed initially. Wiper motors should be ordered only after inspection
determines that replacement is required. Very few vehicles are expected to require rear wiper
motor replacement.
A. Install Mastic Patch & Check For Airbag System
Diagnostic Trouble Codes (DTC's):
1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off.
2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1).
3. Disconnect the liftgate release switch electrical connector (Figure 1).
4. Disconnect the parking hand brake linkage.
5. Set the lower steering column cover aside.
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6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure
2).
7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect
the DRB III to the underdash diagnostic connector (blue connector to the right of the steering
column) and power it up.
8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen.
9. Turn the ignition key tot he "ON" position.
10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN
MENU Screen.
12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen.
14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen.
15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen.
16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen.
17. Record all active DTC's for future reference.
18. Press the PAGE BACK key to return to the DTC TYPE Screen.
19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen.
20. Record all stored DTC's for future reference.
21. Press the PAGE BACK key to continue.
22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present).
23. Press the PAGE BACK key to continue.
24. Turn the ignition key off and disconnect the DRB III.
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25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the
table. If no airbag system DTC's exist, continue with Step 26.
NOTE:
Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any
airbag system diagnostic trouble codes other than those listed above.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Return the vehicle to the customer. No further action is necessary.
B. Replace Rear Wiper Motor
IMPORTANT:
This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the liftgate wiper arm assembly.
3. Open and raise the liftgate.
4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3).
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5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws
(Figure 3).
6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel
screws (Figure 3).
7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3).
8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and
remove the screws (Figure 3).
9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel
(Figure 3).
10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel
from the liftgate.
11. Disconnect the wiper motor electrical connector (Figure 4).
12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor
and bracket assembly from the liftgate and set it aside.
13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate.
Torque the five (5) attaching screws to 35 in-lbs (4 Nm).
14. Connect the wiper motor electrical connector.
15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter
of the panel.
16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3).
CAUTION:
DO NOT over tighten screws as this could damage the trim panel or strip the screws.
17. Install the two (2) screws located in the speaker grille openings (Figure 3).
18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3).
19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3).
20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs.
21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp
assemblies.
22. Close the liftgate.
23. Install the liftgate wiper arm assembly.
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Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7460
24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse
(Fuse # 13) with a new 20 amp fuse (Figure 5).
25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be
repaired, continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Turn the ignition switch to the ON position and exit the vehicle.
31. Connect the negative battery terminal.
32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
C. Repair Driver Airbag Wiring and.or Replace Clockspring
IMPORTANT:
This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble
code.
1. Place the steering wheel in the straight ahead position.
2. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
3. Remove the upper and lower steering column shrouds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7461
4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure
6).
^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5.
^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged,
repair the clockspring wires by taping the damaged area with high quality electrical tape and tie
strap as shown in Figure 6.
^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged,
replace the clockspring assembly as follows:
a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel,
disconnect the airbag module electrical connector and then remove the airbag module from the
steering wheel and set it aside (inflator side down/face up for safety).
b. Disconnect the speed control switch connector (if equipped).
c. Disconnect the horn connector.
d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool
C-3428B), remove the steering wheel.
e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring
pigtail from the steering column.
f. Disconnect the clockspring wiring connector from the back of the clockspring.
g. Unclip the clockspring assembly locating fingers from the steering column and then remove and
discard the clockspring.
h. Snap the new clockspring onto the steering column.
i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring
harness that connects to the ignition switch is between the pigtail and the steering column. Secure
the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6).
j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail
to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA)
(Figure 6).
k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm).
l. Connect the horn connector.
m. Connect the speed control switch connector (if equipped).
n. Connect the airbag module electrical connector and install the airbag module onto the steering
wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm).
5. Install the upper and lower steering column shrouds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7462
6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the
harness tie strap/clip is secured into the hole (Figure 7).
^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage.
Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert
the clip into the hole.
7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage
to the I/P wiring harness as it routes up past the fuse block (Figure 7).
8. Remove the relay access cover.
9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the
tab off of the fuse/relay/kneeblocker bracket (Figure 8).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert
the clip into the hole.
10. Install another mastic patch to the outboard end of the steel tube that routes the transmission
shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8).
11. Install the relay access cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7463
12. Install the lower steering column cover (Figure 1).
13. Connect the liftgate release switch electrical connector (Figure 1).
14. Connect the liftgate release switch electrical connector (Figure 1).
15. Tighten the lower instruments panel cover screws securely.
16. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 9).
17. Slide the cupholder out.
18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9).
19. Slide the console rearward and up to remove.
20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module
(AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7464
21. Install another mastic patch over the rear corner and left edge of the Body Control Module
(BCM) (Figure 10).
22. Install the console assembly.
23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely.
Close the cupholder.
24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely.
25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Turn the ignition switch to the ON position and exit the vehicle.
27. Connect the negative battery terminal.
28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
D. Repair Passenger Airbag Wiring
IMPORTANT:
This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic
trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 11).
3. Slide the cupholder out.
4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11).
5. Slide the console rearward and up to remove.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7465
6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM)
(Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM)
(Figure 12).
8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness
is installed into the hole on the back side of the left center console bracket (Figure 12).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the
clip into the hole.
9. Install the console assembly.
10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely
(Figure 11). Close the cupholder.
11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely.
12. Disconnect the glove box door check straps and allow the door to open fully.
13. Working through the glove box opening, remove the four (4) screws that attach the passenger
airbag module to the I/P bracket (Figure 13).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7466
14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad
and lift it away from the snaps (Figure 14).
15. Hold the passenger airbag module door and raise the module from the opening. DO NOT
disconnect the airbag module electrical connectors.
16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any
chafed or cut wires should be repaired per the Wiring Repair.
17. Install a mastic patch on the edge of the passenger airbag module near the electrical
connectors (Figure 15).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7467
18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical
support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be
repaired per the Wiring Repair Procedure.
19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic
edge cover (Figure 16).
20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50
in-lbs (6 Nm)
21. Connect the glove box door check straps and then close the glove box door.
22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 23.
23. Install the lower steering column cover (Figure 1).
24. Connect the parking hand brake linkage (Figure 1).
25. Connect the liftgate release switch electrical connector (Figure 1).
26. Tighten the lower steering column cover screws securely.
27. Turn the ignition switch to the ON position and exit the vehicle.
28. Connect the negative battery terminal.
29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Wiring Repair Procedure
IMPORTANT:
If airbag system wiring is found chafed or damaged, the wiring should be repaired using the
procedure listed below.
^ If the plastic wire covering is chafed but the wiring strands are NOT damaged:
Tape the damaged area with high quality electrical tape.
^ If the plastic wire covering is chafed and the wiring strands are damaged:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7468
1. Cut the damaged wire in two.
2. Strip 1 inch of insulation from each end of the wire.
3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire.
4. Spread the strands of the wire apart on both of the exposed wire ends.
5. Push the two wire ends together until the strands of the wire are close to the insulation.
6. Twist the wires together.
7. Solder the connection together using rosin core solder.
8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint
until the tubing is tightly sealed and sealant comes out both ends of the tubing.
9. Secure the wire to the harness to prevent chafing or damage to the insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7474
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Customer Safety Information
Clockspring Assembly / Spiral Cable: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Customer Safety Information > Page 7477
Clockspring Assembly / Spiral Cable: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7478
Clockspring Assembly / Spiral Cable: Description and Operation
PURPOSE
The clockspring, mounted on the steering wheel column, behind the steering wheel, is used to
maintain a continuous electrical circuit between the wiring harness and the driver airbag module.
CONSTRUCTION
The clockspring assembly consists of a flat, ribbon like, electrically conductive tape, which winds
and unwinds as the steering wheel is rotated.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7479
Clockspring Assembly / Spiral Cable: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Removal
Clockspring Assembly / Spiral Cable: Service and Repair Removal
REMOVAL
1. Disarm air bag as outlined.
See: Air Bag(s) Arming and Disarming/Service and Repair
2. Set front wheels in straight ahead position. 3. Remove air bag module as outlined under Driver
Air Bag Module, Replace.
See: Air Bag/Service and Repair/Driver Side Airbag Module Replacement
4. Remove speed control switch and electrical connector, if equipped, or cover. 5. Disconnect horn
electrical connector. 6. Remove steering wheel attaching nut; then remove steering wheel using
suitable puller. 7. Remove upper and lower steering column shrouds. 8. Disconnect clockspring two
and four way electrical connectors. 9. Lift clockspring locating fingers, then gently pull clockspring
assembly from steering column.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Removal > Page 7482
Clockspring Assembly / Spiral Cable: Service and Repair Installation
INSTALLATION
1. Snap clockspring on steering column. If clockspring is not properly positioned refer Centering
procedure.
See: Centering
2. Connect clockspring to instrument panel electrical connector, ensuring locator clips and lock tabs
are properly positioned. 3. Install steering column shrouds. Ensure air bag wire is inside shrouds. 4.
Ensure front wheels are in straight ahead position, then install steering wheel, ensuring hub flats
align with clockspring. 5. Pull horn lead through small upper hole, then pull air bag and speed
control leads through larger hole. Ensure leads are not pinched under steering
wheel.
6. Connect horn and air bag electrical connectors at air bag module. 7. Install air bag module as
outlined under Driver Air Bag Module, Replace.
See: Air Bag/Service and Repair/Driver Side Airbag Module Replacement
8. Install speed control switch and electrical connector or uncover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Removal > Page 7483
Clockspring Assembly / Spiral Cable: Service and Repair Centering
Fig. 43 Auto-locking clockspring
CENTERING
NOTE: If rotating part of clockspring is not properly positioned with steering column and front
wheels, clockspring may fail during use. The following procedure must be used if clockspring is not
known to be properly positioned.
1. Position front wheels straight ahead. 2. Depress plastic locking pins to disengage locking
mechanism. 3. With locking mechanism disengaged, rotate clockspring rotor in clockwise direction
to end of travel. Do not apply excessive force. 4. From end of travel, rotate clockspring rotor 2 1/2
turns in counterclockwise direction. The horn wire should be at top and squib wire at bottom.
Visually inspect clockspring for bends or kinks; if indicated, replace clockspring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component
Information > Locations
CCD Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component
Information > Locations > Page 7487
Vehicle will be equipped with one of these three connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations
Impact Sensor: Locations
Located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of.
the center console.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Customer Safety Information > Page 7493
Impact Sensor: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Page 7494
Impact Sensor: Description and Operation
OPERATION
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of. the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Testing
and Inspection > Component Tests and General Diagnostics
Impact Sensor: Component Tests and General Diagnostics
GENERAL INSPECTION
A visual inspection consists of physically looking for possible cause of a malfunction. A careful and
thorough visual inspection of components may quickly identify malfunction cause and eliminate
need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with
diagnostic testing. 1. On all models, turn ignition switch to On. 2. If air bag warning lamp does not
light, proceed with diagnostic testing. 3. If air bag warning lamp fails to go out after ten seconds,
proceed with diagnostic testing. 4. Check air bag control module (ACM) case and brackets for
dents, cracks or deformities. 5. Check ACM connectors and lock levers for damage and terminals
for deformities. 6. Remove air bag module as outlined under Component Service. 7. Never attempt
to measure circuit resistance of air bag module even with a specified tester. 8. Check air bag pad
cover for dents, cracks or deformities. 9. Check air bag module for dents, cracks or deformities.
10. Check hooks and connectors for damage, terminals for deformities and harness for binds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Testing
and Inspection > Component Tests and General Diagnostics > Page 7497
Impact Sensor: Scan Tool Testing and Procedures
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp /
Indicator, Air Bag] > Component Information > Technical Service Bulletins > Airbag - Warning Light Illumination
Air Bag Warning Lamp: Technical Service Bulletins Airbag - Warning Light Illumination
NO: 08-07-98
GROUP: Electrical
DATE: Mar. 6, 1998
SUBJECT: Airbag Warning Light illumination Caused By A Short in The Rear Wiper Motor/Circuit
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
DISCUSSION:
Some subject vehicles may experience a short in the rear wiper motor/circuit causing fuse # 13 to
blow which illuminates the Airbag Warning light in the instrument panel. When a short in the rear
wiper motor/circuit causes fuse # 13 to blow, the Airbag Warning light is "ON" but the airbag
system still receives power through fuse # 20 and is fully functional, providing the same occupant
protection as when the light is not illuminated. However, when this condition occurs, it hides a
proper warning if an airbag system fault were to occur.
Due to the age of the involved vehicles, some owners may prefer to minimize their expense to turn
off the Airbag Warning light.
For owners seeking a less expensive alternative, if the rear wiper motor itself is the source of the
short, the wiper motor wiring connector can be disconnected and isolated. Then, when fuse # 13 is
replaced, the Airbag Warning light will be extinguished, allowing the Airbag Warning light to
indicate real airbag system faults if they should occur. Use a DRB III to check for any stored airbag
Diagnostic Trouble Codes (DTC's).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp /
Indicator, Air Bag] > Component Information > Technical Service Bulletins > Page 7502
Air Bag Warning Lamp: Locations
Located in the Information Center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp /
Indicator, Air Bag] > Component Information > Technical Service Bulletins > Page 7503
Air Bag Warning Lamp: Description and Operation
PURPOSE
The AIR BAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
See Testing and Inspection to find the cause of any customer complaint regarding the AIR BAG
warning lamp, such as: Warning lamp does not come on at all
- Warning lamp stays on
See: Testing and Inspection
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp /
Indicator, Air Bag] > Component Information > Technical Service Bulletins > Page 7504
Air Bag Warning Lamp: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations
Air Bag Control Module And Body Control Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control
Module 4 Way Connector
Air Bag Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control
Module 4 Way Connector > Page 7511
Air Bag Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control
Module 4 Way Connector > Page 7512
Airbag System Control Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer
Safety Information
Supplemental Restraint System (SRS) Control Module: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer
Safety Information > Page 7515
Supplemental Restraint System (SRS) Control Module: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer
Safety Information > Page 7516
Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings
CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF"
and the battery is disconnected. Failure to do so could damage the module.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 7517
Supplemental Restraint System (SRS) Control Module: Description and Operation
OPERATION
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the air bags. The total time between determining to deploy and deflation of the air bag is 1/10th of a
second.
SELF DIAGNOSTIC FUNCTIONS
Whenever the ignition key is turned to the "RUN" or "START" position, the air bag control module
(ACM) performs a lamp check by turning the AIR BAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM
has checked the system and found it to be free of discernible malfunctions. The air bag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the air bag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The
ACM provides diagnostic information about the air bag system to the technician through the DRB
via the CCD bus.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection >
Component Tests and General Diagnostics
Supplemental Restraint System (SRS) Control Module: Component Tests and General Diagnostics
GENERAL INSPECTION
A visual inspection consists of physically looking for possible cause of a malfunction. A careful and
thorough visual inspection of components may quickly identify malfunction cause and eliminate
need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with
diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are
properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag
warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go
out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case
and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for
damage and terminals for deformities. 7. Remove air bag module as outlined under Component
Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified
tester. 9. Check air bag pad cover for dents, cracks or deformities.
10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for
damage, terminals for deformities and harness for binds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 7520
Supplemental Restraint System (SRS) Control Module: Scan Tool Testing and Procedures
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint
System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Page
7521
Supplemental Restraint System (SRS) Control Module: Service and Repair
AIR BAG CONTROL (ACM), REPLACE
1. Disarm air bag system as outlined under Air Bag System Disarming and Arming.
See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair
2. Remove screws attaching lower console to instrument panel support bracket. 3. Remove upper
console attaching screws behind cup holder, then slide console to rear and up to remove. 4.
Disconnect ACM wiring and remove module, then remove ACM mounting screws. 5. Reverse
procedure to install and tighten screws to specifications.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
DISARMING
1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at
least ten minutes after disconnecting battery ground cable before performing any further repairs on
vehicle. The SRS system is
designed to retain enough voltage to deploy air bag for a short time even after battery has been
disconnected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming > Page 7527
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
ARMING
1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side
of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one
is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning
light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate
SRS system is functioning correctly.
5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air
Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 7533
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 (V6-201 3.3L (1994))
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 7534
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 7535
PARTS REQUIRED:
POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 7536
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 7537
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 7538
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 (V6-201 3.3L (1994))
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 7539
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 (V6-201 3.3L (1994))
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 7540
detailed instruction sheet.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 7541
PARTS REQUIRED:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 7542
POLICY: Customer Satisfaction
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 7543
TIME ALLOWANCE:
Failure Code: CG - Customer Satisfaction
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Customer Interest for Seat Belt: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt - High
Extension Effort
Seat Belt: Customer Interest Middle Bench Seat Outer Seatbelt - High Extension Effort
NO: 23-03-94
GROUP: Body
DATE: Jan. 21, 1994
SUBJECT: Middle Bench Seat Left Seat Belt
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES.
SYMPTOM/CONDITION:
High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to
the stowed position.
DIAGNOSIS:
Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair
procedure.
REPAIR PROCEDURE:
This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel.
1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter
trim insert.
2. Remove the silencer material from the back side of the upper quarter trim panel from the area
shown in the illustration.
3. Reverse the procedure in step 1 to reinstall the interior trim.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-20-56-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt High Extension Effort
Seat Belt: All Technical Service Bulletins Middle Bench Seat Outer Seatbelt - High Extension Effort
NO: 23-03-94
GROUP: Body
DATE: Jan. 21, 1994
SUBJECT: Middle Bench Seat Left Seat Belt
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES.
SYMPTOM/CONDITION:
High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to
the stowed position.
DIAGNOSIS:
Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair
procedure.
REPAIR PROCEDURE:
This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel.
1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter
trim insert.
2. Remove the silencer material from the back side of the upper quarter trim panel from the area
shown in the illustration.
3. Reverse the procedure in step 1 to reinstall the interior trim.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-20-56-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Page 7557
Seat Belt: Service and Repair
Front Outboard Seat Belt Left Side
Front Outboard Seat Belt Right Side
FRONT SEAT BELTS OUTBOARD SHOULDER HARNESS/LAP BELT REMOVAL
1. Remove shoulder harness turning loop. 2. Remove B-pillar or quarter trim panels as necessary
to gain access to belt retractor. 3. Remove bolt holding retractor and lower lap belt anchor to
B-pillar. 4. Separate belt from vehicle.
OUTBOARD SHOULDER HARNESS/LAP BELT INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Page 7558
Front Inboard Seat Belt Buckle
INBOARD BUCKLE REMOVAL
1. Remove bolt holding seat belt buckle to seat riser. 2. separate buckle from seat riser. 3.
Disconnect seat belt sensor wire connector, if equipped.
INBOARD BUCKLE INSTALLATION
Reverse the preceding operation.
Rear Shoulder/Lap Belts Left Side
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Page 7559
Rear Shoulder/Lap Belts Right Side
REAR SEAT BELT OUTBOARD SHOULDER HARNESS/LAP BELT REMOVAL
1. Remove interior trim as necessary to gain access to belt retractor. 2. Remove bolt holding lower
lap belt anchor to floor bracket. 3. Remove bolt holding belt retractor to inner quarter panel. 4.
Separate belt from vehicle.
OUTBOARD SHOULDER HARNESS LAP BELT INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information
> Service and Repair
Seat Belt Height Adjuster: Service and Repair
Shoulder Harness Height Adjuster
1. Remove B-pillar trim or quarter trim panel. 2. Remove bolts holding adjuster to B-pillar. 3.
Separate adjuster from vehicle. 4. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7568
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7569
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7570
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7571
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7572
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7573
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations
Impact Sensor: Locations
Located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of.
the center console.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Customer Safety Information > Page 7579
Impact Sensor: Technician Safety Information
WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the
event of an accident.
NOTE: Service and general information labels about the air bag system can be found on the
driver's sun visor, the glove box door, and in the engine compartment.
PRECAUTIONS
Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air
bag module.
Because this system is a sensitive, complex electro-mechanical unit, before attempting to
diagnose, remove or install any air bag system component, you must first disarm air bag system as
outlined. Failure to do this could result in accidental airbag deployment and possible personal
injury.
The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials
are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. In addition, the passenger airbag module contains argon gas pressurized
to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not
puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding
93° C (200° F).
The fasteners, screws and bolts used for air bag components have special coatings and are
specifically designed for the air bag system. They must never be replaced with substitutes. If
fastener replacement is required, use correct fasteners provided in service package.
Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog.
Substitute parts may appear interchangeable, but internal differences may result in inferior
occupant protection.
When a steering column has an airbag module attached, never place the column on the floor or
any other surface with the steering wheel or air bag module face down.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult. Accidental airbag deployment could occur.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Page 7580
Impact Sensor: Description and Operation
OPERATION
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of. the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Testing and Inspection > Component Tests and General Diagnostics
Impact Sensor: Component Tests and General Diagnostics
GENERAL INSPECTION
A visual inspection consists of physically looking for possible cause of a malfunction. A careful and
thorough visual inspection of components may quickly identify malfunction cause and eliminate
need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with
diagnostic testing. 1. On all models, turn ignition switch to On. 2. If air bag warning lamp does not
light, proceed with diagnostic testing. 3. If air bag warning lamp fails to go out after ten seconds,
proceed with diagnostic testing. 4. Check air bag control module (ACM) case and brackets for
dents, cracks or deformities. 5. Check ACM connectors and lock levers for damage and terminals
for deformities. 6. Remove air bag module as outlined under Component Service. 7. Never attempt
to measure circuit resistance of air bag module even with a specified tester. 8. Check air bag pad
cover for dents, cracks or deformities. 9. Check air bag module for dents, cracks or deformities.
10. Check hooks and connectors for damage, terminals for deformities and harness for binds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7583
Impact Sensor: Scan Tool Testing and Procedures
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Locations
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Locations > Page 7590
Keyless Entry Module: Diagrams
Remote Keyless Entry Module Connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Service and Repair > Programming Module
Keyless Entry Module: Service and Repair Programming Module
PROGRAMMING RKE MODULE
The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is
interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be
programmed into the Body Control Module (BCM). A functional key fob transmitter is required to
program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan
tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm
(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds
(maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC
button. A single chime will sound to verify that the
RKE module is set to receive the new VAC.
(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30
seconds or when ignition switch is turned OF{ the RKE
module will end the programming mode. A single chime will sound to verify that the RKE module
will no longer receive additional VAC(s).
(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation
using each key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 7593
Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement
REMOVAL
(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.
INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Remote Keyless Entry - Transmitter
Malfunction
Keyless Entry Transmitter: Technical Service Bulletins Remote Keyless Entry - Transmitter
Malfunction
NO.: 08-51-93
GROUP: Electrical
DATE: Oct. 15, 1993
SUBJECT: Remote Keyless Entry System
MODELS:
1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
SYMPTOM/CONDITION:
Some vehicles may require the Remote Keyless Entry (RKE) transmitter button(s) to be repeatedly
depressed to obtain a response from the system.
NOTE: AS-BODY VEHICLES RESPOND DIFFERENTLY TO RKE INPUTS WHEN COMPARED
TO THE SIMILAR SYSTEM USED PREVIOUSLY ON AC/AY-BODY VEHICLES. AS-BODY
VEHICLES HAVE A SHORT DELAY AFTER A RKE TRANSMITTER BUTTON IS DEPRESSED
BEFORE EITHER THE ILLUMINATED ENTRY OR HORN CHIRP IS ACTIVATED. THIS DELAY
IS NORMAL FOR AS-BODY VEHICLES BUT DID NOT OCCUR ON PREVIOUS AC/AY-BODY
VEHICLES.
DIAGNOSIS:
Open the transmitter case to access the batteries. If a white pentastar is NOT readily visible on the
printed circuit board, perform the repair procedure. If the printed circuit board has a white
pentastar, this TSB does not apply and the procedure outlined beginning on page 214 of the Body
Diagnostic Procedures Manual (Publication No. 81- 699-0442) should be used.
PARTS REQUIRED:
2 Transmitter 4469341
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitters.
1. Obtain two new transmitters (P/N 4469341) and verify they have a white pentastar on their
printed circuit boards.
2. Using the procedure outlined on page 8P-5 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105) program the RKE transmitters.
NOTE: IN THE SPIRIT OF CUSTOMER ONE, AND IN CASE THEY WERE NOT TOLD AT THE
TIME OF DELIVERY, THIS WOULD BE AN EXCELLENT TIME TO ADVISE THE CUSTOMER
THE HORN CHIRP FEATURE CAN BE CANCELED WHEN THE NEW RKE TRANSMITTERS
ARE PROGRAMMED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-28-90 0.2 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 7598
Keyless Entry Transmitter: Description and Operation
Normal operation range is up to about a distance of 7 meters (23 ft.) of the vehicle. Range may be
better or worse depending on the environment around the vehicle. Closeness to a radio frequency
transmitter such as a radio station tower may degrade operational range, while range in an open
field will be enhanced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming
Keyless Entry Transmitter: Service and Repair Transmitter Programming
PROGRAM REMOTE KEYLESS ENTRY
- Open and lower glove box door.
- Locate program line a dark green wire with a molded insulator on the end. Located behind and
lower end of the glove box.
- Turn ignition switch to the ON position.
- Connect the program line from the Remote Keyless Entry Module to ground. the door locks will
lock and unlock to indicate the receiver is ready to receive transmitter code. Liftgate solenoid will
not cycle.
- Press any button on the transmitter to set code. If there is a second transmitter it has to be set at
this time. The locks will cycle to confirm programming.
- Disconnect the program line from ground. This returns the system to its normal operation mode.
- Install glove box to original position.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming > Page 7601
Keyless Entry Transmitter: Service and Repair Battery Replacement
The batteries can be removed without special tools and are readily available at local retail stores.
The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years.
CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary.
Hands must be clean dry.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions
Driver/Vehicle Information Display: Technical Service Bulletins Instruments Calibration/Diagnostics Revisions
NUMBER: 08-78-94
GROUP: Electrical
DATE: Dec. 30, 1994
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**
Models: 1994 Town & Country/Caravan/Voyager - Publication No. 81-370-4105
DESCRIPTION OF CHANGES
Calibration Description & Self Diagnosis
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 7606
8C-2
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 7607
8C-4
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7610
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7611
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7612
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7613
Driver/Vehicle Information Display: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7614
Warning Lamp Center Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7615
Driver/Vehicle Information Display: Electrical Diagrams
Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7616
Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7617
Warning Lamp Center (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7618
Warning Lamp Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Page 7619
Driver/Vehicle Information Display: Service and Repair
1. Remove instrument panel cluster bezel and left panel silencer, then disconnect parking brake
linkage. 2. Remove five cover attaching screws and lower cover, then disconnect all wire
connectors. 3. Remove steering column covers, then remove four cluster screws. 4. On models
with electronic instruments, proceed as follows:
a. Remove four cluster securing screws and four mask housing screws b. Rotate mask down, then
disconnect buttons and PRNDL indicator.
Fig. 9 Mechanical Instrument Cluster Removal
5. On models with mechanical instruments, rotate cluster and disconnect connector. 6. On all
models, remove two transmission indicator screws and cluster. 7. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control
Relay > Component Information > Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Door Speaker
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Door Speaker > Page 7632
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Door Speaker > Page 7633
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Audio Control Relay > Component Information > Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations > Page 7641
Keyless Entry Module: Diagrams
Remote Keyless Entry Module Connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module
Keyless Entry Module: Service and Repair Programming Module
PROGRAMMING RKE MODULE
The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is
interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be
programmed into the Body Control Module (BCM). A functional key fob transmitter is required to
program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan
tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm
(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds
(maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC
button. A single chime will sound to verify that the
RKE module is set to receive the new VAC.
(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30
seconds or when ignition switch is turned OF{ the RKE
module will end the programming mode. A single chime will sound to verify that the RKE module
will no longer receive additional VAC(s).
(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation
using each key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 7644
Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement
REMOVAL
(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.
INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7650
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7651
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7652
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7653
Trailer Connector: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7654
Trailer Tow System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7659
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7660
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7661
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7662
Trailer Connector: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7663
Trailer Tow System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations
Compass Mini-trip Module Connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions
Trip Computer: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7669
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7670
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7671
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7672
Trip Computer: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7673
Trip Computer: Connector Views
Overhead Console Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7674
Trip Computer: Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7675
Overhead Console Lamp With Mini-Trip Computer (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7676
Overhead Console Lamp With Mini-Trip Computer (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Page 7677
Trip Computer: Description and Operation
Compass Mini-trip Module
PURPOSE:
The compass/mini-trip module is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy, distance to empty (DTE), elapsed time
(ET), and trip odometer (ODO).
OPERATION:
The information needed for the traveler functions is received over the CCD bus from the body
control module.
NOTE: If the compass mini-trip module has been replaced, it may be necessary to reset the
calibration.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information >
Adjustments > Setting Compass Variance
Trip Computer: Adjustments Setting Compass Variance
DEFINITION: Variance is the difference between magnetic north and geographic north. To
determine the variance for the area you are in, refer to the zone map below. The number shown for
your area is the variance number for your area (continued on the following page).
1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold
down both the US/METRIC button and the STEP button for 5 seconds.
NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and
enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number and resume normal operation.
NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can
cause the compass to give false readings.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information >
Adjustments > Setting Compass Variance > Page 7680
Trip Computer: Adjustments Setting the Compass
The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be
displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the
vehicle has gone in three complete circles without stopping, in an area free of magnetic
disturbance.
If the module displays the temperature while the compass is blank, the vehicle must be
demagnetized.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door
Ajar Lamp - Flickers/Locks Cycle Repeatedly
Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door
Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 7691
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr >
94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr >
94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 7697
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Technical Service Bulletins > Page 7698
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions
Body Controller: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7701
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7702
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7703
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7704
Body Controller: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7705
Body Controller: Connector Views
Body Control Module Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7706
Body Control Module Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7707
BCM Natural Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Diagrams > Diagram Information and Instructions > Page 7708
BCM Blue Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Application and ID > BCM Identification
Body Controller: Application and ID BCM Identification
There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument
cluster.
- The other supports the electronic instrument cluster.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Application and ID > BCM Identification > Page 7711
Body Controller: Application and ID Glossary of Terms
BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Application and ID > Page 7712
Body Controller: Description and Operation
PURPOSE
The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these
systems.
- Is the only module that has the capability of providing both bias and termination on the CCD bus
system.
- Is used to store odometer information displayed in the electronic instrument cluster.
OPERATION
The body systems are monitored by individual control modules, which send information about their
operation to the body control module over the CCD (Chrysler Collision Detection multiplex system)
bus. Through the CCD bus, information about the operation of vehicle components and circuits is
relayed to the appropriate module(s).
- Each module receives the same information about a component or circuit as another module
does.
- This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
BODY SYSTEM COVERAGE:
- Automatic Door Locks
- Compass/mini-trip Module
- Courtesy Lamps
- Electronic Instrument Cluster (EIC)
- Electro/mechanical Instrument Cluster
- Mechanical Instrument Cluster (MIC)
- Illuminated Entry
- Remote Keyless Entry (RKE)
- Intermittent Wipers
- Liftgate Release
NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board
diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications
(CCD) Bus/Testing and Inspection for diagnosis and repair procedures.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
GLOSSARY OF TERMS
BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus)
CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called
"diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument
Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Testing and Inspection > Component Tests and General Diagnostics
Body Controller: Component Tests and General Diagnostics
Diagnostic Notes - Read First
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
NOTE: These diagnostics are based on the failure condition or symptom being present at the time
of diagnosis.
TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic
codes or error messages may occur.
Be careful when performing electrical tests to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components and will sometimes set a second code, making
diagnosis of the original problem more difficult.
WARNINGS:
- When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
- When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests.
To efficiently diagnose CCD bus problems follow these six steps:
1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5.
Repair the Isolated Problem 6. Verify Proper Operation
ROAD TESTING
Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and
to verify the repair.
CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled.
- During the test drive, do not try to read the scan tool screen while in motion.
- Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant
available to operate the scan tool.
TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is
not set or if it is set incorrectly, any speed-related accessories will not operate or will operate
inaccurately.
- This includes the speedometer, speed control, rolling door locks, and other devices that are
operated by the powertrain and body controllers.
- For instructions on setting the pinion factor, see the appropriate transmission section.
Description of On-Board Diagnostics
A scan tool is required to read body system trouble codes. However, not all body system problems
have a corresponding trouble code.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7715
Body Controller: Scan Tool Testing and Procedures
If the scan tool Does Not Power Up;
Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link
connector cavity 16).
If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully
charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] >
Component Information > Testing and Inspection > Page 7716
Body Controller: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge
- Voltmeter
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service
Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose
Cabin Ventilation Duct: Customer Interest Left B Post Exhauster - Loose
NO: 23-59-94
GROUP: Body
DATE: Aug. 5, 1994
SUBJECT: Left "B"-Post Body Exhauster Retention
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may
cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with
very little assistance.
DIAGNOSIS:
Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the
repair procedure if the exhauster is loose of missing.
PARTS REQUIRED:
AR 82300234 Sealant, RTV
AR 4475320 Exhauster, Body
REPAIR PROCEDURE:
This bulletin involves adhering the "B"-post body exhauster to the "B"-post.
1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320.
2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side
flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration).
3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place.
4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may
have squeezed out from between the "B"-post body
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service
Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose > Page 7725
exhauster and the "B"-post.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-89-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose
Cabin Ventilation Duct: All Technical Service Bulletins Left B Post Exhauster - Loose
NO: 23-59-94
GROUP: Body
DATE: Aug. 5, 1994
SUBJECT: Left "B"-Post Body Exhauster Retention
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may
cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with
very little assistance.
DIAGNOSIS:
Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the
repair procedure if the exhauster is loose of missing.
PARTS REQUIRED:
AR 82300234 Sealant, RTV
AR 4475320 Exhauster, Body
REPAIR PROCEDURE:
This bulletin involves adhering the "B"-post body exhauster to the "B"-post.
1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320.
2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side
flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration).
3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place.
4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may
have squeezed out from between the "B"-post body
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose
> Page 7731
exhauster and the "B"-post.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-89-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins >
Windshield/Cowl - Squeak Elimination
Cowl: Technical Service Bulletins Windshield/Cowl - Squeak Elimination
NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Squeak Noise At The Base Of The Windshield
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
Water soluble support spacers are used in the windshield installation process at the assembly plant
to properly position the windshield. During the transit and vehicle predelivery processes, if enough
water does not come in contact with the windshield support spacers, they may not dissolve as
intended and may cause a squeaking noise. Typically, enough water contacts the windshield
support spacers during a car wash.
Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the
base of the windshield (refer to the illustration). If the support spacers are still in place, raise the
cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve.
This will prevent the customer from experiencing a squeak condition on the new vehicle.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
System Information > Service and Repair
Front Door Handle: Service and Repair
Outside Handle/Lock Cylinder
1. Remove door trim panel and water shield as necessary to gain access to outside door handle. 2.
Disconnect lock cylinder linkage from door latch. 3. Disconnect latch release linkage from door
latch. 4. Disconnect illuminated entry switch wire connector. 5. Remove nut holding outside handle
retaining bracket to door panel and separate bracket from door. 6. Lift lock cylinder linkage upward
to parallel back of outside handle. 7. Separate outside handle from door.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Information > Service and Repair
Front Door Hinge: Service and Repair
Front Door
REMOVAL
1. Remove front fender wheelhouse splash shield. 2. Support door on a suitable lifting device. 3.
Drive out hinge pin on the effected hinge. 4. Remove bolts holding hinge to hinge pillar and
separate hinge form vehicle.
INSTALLATION
Reverse the preceding operation. Align door to achieve 6 mm (0.240 in.) gap to all surrounding
panels and flush across gaps.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Adjustments
Front Door Latch: Adjustments
LATCH/LOCK CONTROL ADJUSTMENTS
The lock knob, inside release handle and outside release handle can be adjusted when door latch
components are replaced or do not operate properly.
Lock Knob Adjuster
LOCK KNOB ADJUSTMENT
1. Remove sliding door trim panel. 2. Release sliding door latch and slide the door open about 100
mm (4 in.). 3. Through elongated slot at the bottom of the control, loosen the socket head screw
holding lock mechanism together. 4. Pull the lock link rod forward locking the latch. 5. Tighten
socket head screw to hold lock mechanism together. 6. Test door lock operation 7. Install door trim
panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Adjustments > Page 7748
Front Door Latch: Service and Repair
Front Door Latch
1. Remove door trim panel and water shield as necessary to gain access to door latch. 2.
Disconnect all linkage rods from latch. 3. Disconnect power door lock actuator wire connector. 4.
Remove screws holding latch to door end frame. 5. Separate door latch from door.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
1. Lower the door glass.
2. If the vehicle is equipped with power windows, disconnect the battery negative cable.
3. Remove the screw holding the door latch handle bezel to the door trim panel. Remove the bezel
from the door.
4. Remove the screw holding the upper door trim to the side view mirror frame.
5. Remove plugs and screws holding the trim to the door above the map pocket.
6. Remove the plug and screw that holds the bottom rear corner of the trim panel to the door.
7. Remove the plugs and screws holding the armrest to the trim panel.
8. Remove the window crank (if equipped with manual windows).
9. Disengage the trim clips that hold the trim panel to the perimeter door inner panel.
10. Lift trim panel upwards to disengage barb clips at top of trim panel.
11. Disconnect courtesy lamp, power window switch, power lock switch electrical connectors (if
equipped).
12. Remove trim panel from door.
INSTALLATION
1. Connect courtesy lamp, power window switch, power lock switch electrical connectors (if
equipped).
2. Install trim panel by pushing in and down at the same time. Pushing down will engage the barb
clips at the top of the trim panel.
3. Push the trim clips in at the perimeter of the door inner panel.
4. Install the window crank (if equipped with manual windows).
5. Install the screws and plugs that hold the armrest to the trim panel.
6. Install the screw and plug into the bottom rear corner of the trim panel.
7. Install the screws and plugs that hold the trim panel to the door above the map pocket.
8. Install the screw holding the upper door trim to the side view mirror frame.
9. Install the door latch handle bezel and its screw to the door trim panel.
10. Connect the negative battery cable if it was removed (if equipped with power windows).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip >
Component Information > Service and Repair > Front Door Frame Rear Molding
Front Door Weatherstrip: Service and Repair Front Door Frame Rear Molding
Belt Moulding And Weatherstrip
1. Remove belt molding and weatherstrip as necessary to clear door frame molding removal path.
2. Remove glass run weatherstrip to gain access to molding clips. 3. Disengage clips holding door
frame molding to door frame 4. Separate molding from door. 5. Reverse the preceding operation
for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip >
Component Information > Service and Repair > Front Door Frame Rear Molding > Page 7756
Front Door Weatherstrip: Service and Repair Front Door Belt Molding and Weatherstrip
VAN ONLY
Belt Moulding And Weatherstrip
1. Remove door glass. 2. Remove side view mirror. 3. Remove screws holding belt molding and
weatherstrip to door panel. 4. Separate belt molding and weatherstrip from door. 5. Reverse the
preceding operation for installation.
WAGON ONLY
Belt Moulding And Weatherstrip
1. Remove door glass. 2. Remove side view mirror. 3. Remove door glass run weatherstrip. 4.
Disengage clips holding door frame molding to door frame. 5. Remove screws holding belt molding
and weatherstrip to door panel. 6. Separate belt molding and weatherstrip from door. 7. Reverse
the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass
> Front Door Window Glass Weatherstrip > Component Information > Service and Repair
Front Door Window Glass Weatherstrip: Service and Repair
Glass Channel And Run Weatherstrip
1. Lower door glass to down position. 2. Remove side view mirror as necessary to gain clearance
for weatherstrip removal. 3. Pull glass run weatherstrip from door frame channel. 4. Reverse the
preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Adjustments > Sliding Side Door, Interior Handle
Sliding Door Handle: Adjustments Sliding Side Door, Interior Handle
Inside Release Handle Adjuster
1. Remove sliding door trim panel. 2. Release sliding door latch and slide the door open about 100
mm (4 in.). 3. Loosen socket head screw holding linkage bell crank together. 4. Using a screw
driver through the elongated slot behind inside door handle, push linkage rearward to take up all
free travel. 5. Tighten socket head screw to hold bell crank together. 6. Test inside door handle
operation. 7. Install door trim panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Adjustments > Sliding Side Door, Interior Handle > Page 7766
Sliding Door Handle: Adjustments Sliding Side Door, Exterior Handle
Outside Release Handle Adjuster
1. Remove sliding door trim panel. 2. Release sliding door latch and slide the door open about 100
mm (4 in.). 3. Loosen socket head screw holding central pivot cam together. 4. Hold central pivot
against the outside door handle actuator button. 5. Tighten socket head screw to hold central pivot
cam together. 6. Test outside door handle operation. 7. Install door trim panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Service and Repair > Interior Door Handle
Sliding Door Handle: Service and Repair Interior Door Handle
Inside Latch/Lock Control
1. Remove sliding door trim panel and water shield. 2. Remove screws holding inside door handle
bezel to latch/lock control assembly. 3. Separate bezel from control. 4. Remove bolts holding
latch/lock control to inner door panel. 5. Pull control away from inner door panel and disconnect
linkage rods and power door lock wire connector, if equipped. 6. Separate control from door. 7.
Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Service and Repair > Interior Door Handle > Page 7769
Sliding Door Handle: Service and Repair Exterior Door Handle
Sliding Door Outside Release Handle
1. Remove sliding door trim panel and water shield. 2. Remove screws holding inside latch/lock
control assembly to door inner panel. 3. Disconnect linkage rods and wire connectors as necessary
to gain access to outside handle mounting. 4. Disconnect lock rod from lock cylinder arm. 5.
Remove nuts holding mounting plate to inner door panel and separate plate from door. 6. Separate
outside handle from door. 7. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
REMOVAL
Sliding Door Trim Panel
1. Close the sliding door.
2. Remove the plug and screw at the rearward center of door trim panel.
3. Remove the hidden screw from the upper rearward corner of the carpet insert.
4. Remove the screws along the bottom of the trim panel used to hold the trim panel to the door.
5. Disengage the trim clips holding the trim panel to the door. These are located around the
perimeter of the door.
6. Lift up on the trim panel to disengage the barb clips at the top of the trim panel.
7. Remove the trim panel.
INSTALLATION
1. Install the trim panel by pushing in and down at the same time (this is done to snap the barb
clips into place at the top of the trim panel).
2. Install the trim clips around the perimeter of the door.
3. Install the screws along the bottom of the trim panel that hold the trim panel to the door.
4. Install the hidden screw behind the upper rearward corner of the carpet insert.
5. Install the screw and plug at the rearward center of the door trim panel (this screw should be
installed just under the rear of the sliding door window).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Sliding Door Latch/Lock Linkage
SLIDING DOOR LATCH/LOCK LINKAGE REMOVAL
1. Remove sliding door trim panel and water shield. 2. Remove latch/lock control. 3. Disconnect
ends of linkage rod to be replaced. 4. Separate linkage rod from door.
SLIDING DOOR LATCH/LOCK LINKAGE INSTALLATION
Reverse the preceding operation.
Sliding Door Rear Latch
SLIDING DOOR REAR LATCH REMOVAL
1. Remove sliding door trim panel and water shield as necessary. 2. Unlatch door and allow to
swing outward, do not open. 3. Disconnect linkage rods from rear latch. 4. Remove screws holding
latch to door end frame. 5. Separate latch from door end frame and remove through access hole in
inner door panel.
SLIDING DOOR REAR LATCH INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Fuel Door Remote Cable
1. Remove interior trim as necessary to gain access to cable. 2. Remove screw holding hood
release handle to mechanism. Separate handle from mechanism. 3. Remove screws holding
release mechanism to seat riser. Separate mechanism from riser. 4. Disengage cable casing from
slot on mechanism. 5. Remove nut holding cable end to fuel fill opening. 6. Remove cable from
vehicle. 7. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Description and Operation
Power Trunk / Liftgate Lock Actuator: Description and Operation
Liftgate Release - This option has a button located on the left side of the instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair
Trunk / Liftgate Latch: Service and Repair
Lift Gate Latch
1. Raise lift gate to open position. 2. Remove lift gate trim panel. 3. Disconnect linkage rods from
latch. 4. Remove screws holding latch to lift gate. 5. Separate latch from lift gate.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Locations > Page 7790
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component
Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 237794 > Oct > 94 > Body
Cladding - Interferes With Use Of Jack
Lower Side Moulding / Trim: Customer Interest Body Cladding - Interferes With Use Of Jack
NO: 23-77-94
GROUP: Body
DATE: Oct. 28, 1994
SUBJECT: Body Cladding Interferes With Use Of Jack
MODELS:
1994 - 1995 (AS) Caravan
SYMPTOM/CONDITION:
Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with
the flange of the body cladding on some LE and ES Caravan models.
DIAGNOSIS:
Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional
clearance is needed, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves creating a notch in the body side cladding.
1. Raise the vehicle on an appropriate lifting device.
2. Cut out the template illustrated above.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component
Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 237794 > Oct > 94 > Body
Cladding - Interferes With Use Of Jack > Page 7803
3. Position the template on the bottom flange of the cladding so the notch of the template is
centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the
centers for the two 3/8" holes.
4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8".
5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of
the holes drilled in step 4.
6. Repeat steps 3 through 5 for the other side.
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-38-91 0.4 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 237794 > Oct >
94 > Body Cladding - Interferes With Use Of Jack
Lower Side Moulding / Trim: All Technical Service Bulletins Body Cladding - Interferes With Use Of
Jack
NO: 23-77-94
GROUP: Body
DATE: Oct. 28, 1994
SUBJECT: Body Cladding Interferes With Use Of Jack
MODELS:
1994 - 1995 (AS) Caravan
SYMPTOM/CONDITION:
Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with
the flange of the body cladding on some LE and ES Caravan models.
DIAGNOSIS:
Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional
clearance is needed, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves creating a notch in the body side cladding.
1. Raise the vehicle on an appropriate lifting device.
2. Cut out the template illustrated above.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 237794 > Oct >
94 > Body Cladding - Interferes With Use Of Jack > Page 7809
3. Position the template on the bottom flange of the cladding so the notch of the template is
centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the
centers for the two 3/8" holes.
4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8".
5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of
the holes drilled in step 4.
6. Repeat steps 3 through 5 for the other side.
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-38-91 0.4 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle
Drifts Left
Cross-Member: Customer Interest Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left
NO: 22-07-94
GROUP: Tires and Wheels
DATE: Oct. 21, 1994
SUBJECT: Tire Leads/Drifts Left
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11,
1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE
BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING
1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL
REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift
tendencies.
DIAGNOSIS:
Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to
the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight
drift to the left is expected and normal.
If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following
diagnostic procedures should be followed:
A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected,
return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel
assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is
unchanged, perform step B of the diagnosis.
B. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure.
PARTS REQUIRED:
1 6502553 Screw and Washer Assembly
REPAIR PROCEDURE:
This bulletin involves repositioning the front crossmember.
1. Raise the vehicle on a hoist that leaves the front wheels unsupported.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle
Drifts Left > Page 7819
2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame
structure (Refer to the Illustration).
3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment
position of the front crossmember.
4. Loosen the two front and right rear front crossmember attachments.
5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front
crossmember assembly forward using the right rear attachment as the pivot point for the rotation
(looking at the front crossmember from underneath the vehicle, this will be a counterclockwise
rotation). Rotate the crossmember until it contacts the left rear crossmember fastener.
6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is
held against the left rear fastener.
7. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
**8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-00-01-95 (Includes Alignment) 1.0 Hrs.
FAILURE CODE: **LL - Leads Left**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires
- Vehicle Drifts Left
Cross-Member: All Technical Service Bulletins Crossmember/Alignment/Wheels/Tires - Vehicle
Drifts Left
NO: 22-07-94
GROUP: Tires and Wheels
DATE: Oct. 21, 1994
SUBJECT: Tire Leads/Drifts Left
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11,
1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE
BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING
1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL
REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift
tendencies.
DIAGNOSIS:
Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to
the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight
drift to the left is expected and normal.
If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following
diagnostic procedures should be followed:
A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected,
return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel
assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is
unchanged, perform step B of the diagnosis.
B. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure.
PARTS REQUIRED:
1 6502553 Screw and Washer Assembly
REPAIR PROCEDURE:
This bulletin involves repositioning the front crossmember.
1. Raise the vehicle on a hoist that leaves the front wheels unsupported.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires
- Vehicle Drifts Left > Page 7825
2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame
structure (Refer to the Illustration).
3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment
position of the front crossmember.
4. Loosen the two front and right rear front crossmember attachments.
5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front
crossmember assembly forward using the right rear attachment as the pivot point for the rotation
(looking at the front crossmember from underneath the vehicle, this will be a counterclockwise
rotation). Rotate the crossmember until it contacts the left rear crossmember fastener.
6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is
held against the left rear fastener.
7. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
**8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-00-01-95 (Includes Alignment) 1.0 Hrs.
FAILURE CODE: **LL - Leads Left**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and
Repair
Carpet: Service and Repair
Floor Carpet And Silencers
1. Remove full forward console, if equipped. 2. Remove Seats. 3. Remove door sill scuff plates. 4.
Remove rear seat anchor well bezels, if equipped. 5. Fold carpet to center of vehicle and remove
through sliding door. 6. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component
Information > Diagrams > Diagram Information and Instructions
Console Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 7835
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 7836
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 7837
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 7838
Console Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 7839
Console Lamp: Electrical Diagrams
Headlamp Switch Controlled Interior & Console Lamps (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 7840
Headlamp Switch Controlled Interior & Console Lamps (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] >
Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
DISARMING
1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at
least ten minutes after disconnecting battery ground cable before performing any further repairs on
vehicle. The SRS system is
designed to retain enough voltage to deploy air bag for a short time even after battery has been
disconnected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] >
Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7846
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
ARMING
1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side
of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one
is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning
light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate
SRS system is functioning correctly.
5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air
Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > Headliner - Fastener Pins
Headliner: Technical Service Bulletins Headliner - Fastener Pins
NO: 23-20-94 GROUP: Body DATE: Feb. 25, 1994
SUBJECT: Headliner Fastener Pins
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A new style of headliner fastener pin will be used on the subject vehicles beginning 3/21/94 (MDH
0321XX). The new pins will require replacement any time they are removed because of damage to
the original pins caused during removal.
Part numbers for replacement pins are listed below:
AR JB66PB7 Blue
AR JB66PD5 Quartz
AR JB66PF6 Driftwood
AR JB66PM6 Red
These parts numbers are for the old style pins and will be superseded by the new style pin in
approximately 30 days. The new style pins provide greater retention than the old style and should
be used if difficulty in keeping the pin(s) in place is experienced.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > Page 7851
Headliner: Service and Repair
Headliner
1. Remove overhead console, if equipped. 2. Remove inboard sun visor clips, if equipped. 3.
Remove roof rail moldings as necessary to gain clearance for head lining removal. 4. Remove
sliding door upper track cover. 5. Remove right quarter trim panel. 6. Remove dome lamp, if
equipped. 7. Separate head lining from vehicle. 8. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > Customer Interest: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt - High Extension Effort
Trim Panel: Customer Interest Middle Bench Seat Outer Seatbelt - High Extension Effort
NO: 23-03-94
GROUP: Body
DATE: Jan. 21, 1994
SUBJECT: Middle Bench Seat Left Seat Belt
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES.
SYMPTOM/CONDITION:
High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to
the stowed position.
DIAGNOSIS:
Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair
procedure.
REPAIR PROCEDURE:
This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel.
1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter
trim insert.
2. Remove the silencer material from the back side of the upper quarter trim panel from the area
shown in the illustration.
3. Reverse the procedure in step 1 to reinstall the interior trim.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-20-56-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Trim Panel: > 235394 > Jul > 94 > Lift Gate Trim Panel - Cracked
Trim Panel: All Technical Service Bulletins Lift Gate Trim Panel - Cracked
NO: 23-53-94
GROUP: Body
DATE: Jul. 8, 1994
SUBJECT: Liftgate Trim Panel Cracking
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A new type of screw is being used during vehicle assembly to attach the liftgate trim panel to the
top of the liftgate beginning the week of 6/27/94. These screws are undercut between the bottom of
the head and the threads of the screw. This style of screw will act as though it is stripped when it is
installed. When removing these screws, the trim panel must be pulled back/away slightly from the
liftgate in order for the threads of the screws to engage the sheetmetal of the liftgate so the screws
can then be screwed out.
These screws provide the proper retention of the trim panel while preventing over tightening of the
screws that leads to cracks in the liftgate trim panel.
NOTE:
WHENEVER A LIFTGATE TRIM PANEL IS REPLACED, ESPECIALLY BECAUSE OF
CRACKING, ALWAYS USE THE NEW STYLE SCREWS (P/N 6035556).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Trim Panel: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt
- High Extension Effort
Trim Panel: All Technical Service Bulletins Middle Bench Seat Outer Seatbelt - High Extension
Effort
NO: 23-03-94
GROUP: Body
DATE: Jan. 21, 1994
SUBJECT: Middle Bench Seat Left Seat Belt
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES.
SYMPTOM/CONDITION:
High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to
the stowed position.
DIAGNOSIS:
Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair
procedure.
REPAIR PROCEDURE:
This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel.
1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter
trim insert.
2. Remove the silencer material from the back side of the upper quarter trim panel from the area
shown in the illustration.
3. Reverse the procedure in step 1 to reinstall the interior trim.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-20-56-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Trim Panel: > 235394 > Jul > 94 > Lift Gate Trim Panel - Cracked
Trim Panel: All Technical Service Bulletins Lift Gate Trim Panel - Cracked
NO: 23-53-94
GROUP: Body
DATE: Jul. 8, 1994
SUBJECT: Liftgate Trim Panel Cracking
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
A new type of screw is being used during vehicle assembly to attach the liftgate trim panel to the
top of the liftgate beginning the week of 6/27/94. These screws are undercut between the bottom of
the head and the threads of the screw. This style of screw will act as though it is stripped when it is
installed. When removing these screws, the trim panel must be pulled back/away slightly from the
liftgate in order for the threads of the screws to engage the sheetmetal of the liftgate so the screws
can then be screwed out.
These screws provide the proper retention of the trim panel while preventing over tightening of the
screws that leads to cracks in the liftgate trim panel.
NOTE:
WHENEVER A LIFTGATE TRIM PANEL IS REPLACED, ESPECIALLY BECAUSE OF
CRACKING, ALWAYS USE THE NEW STYLE SCREWS (P/N 6035556).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings
Trim Panel: Service and Repair A-Pillar and Roof Rail Moldings
Interior Trim
1. Remove grab handle, if equipped. 2. Remove windshield side garnish molding. 3. Remove plug
and screw holding A-pillar trim to roof rail. 4. Disengage fasteners holding A-pillar trim to A-pillar. 5.
Separate A-pillar trim from vehicle. 6. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7876
Trim Panel: Service and Repair Left Quarter Trim Panel
Quarter Trim Panel
Quarter Trim Panel With Rear A/C
1. Remove ash tray. 2. Remove screw holding quarter trim insert to quarter trim from inside ash
tray opening. 3. Pull outward at bottom of trim insert to disengage clips holding insert to quarter
trim.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7877
4. Lift insert upward and separate quarter trim insert from vehicle. 5. Remove screws holding lower
quarter trim panel to inner quarter panel. 6. Separate lower quarter trim from vehicle. 7. Remove
covers and bolts holding shoulder harness turning loops to upper quarter panel. 8. Remove bolts
holding outboard seat belt anchor to floor. 9. Remove seat belt retractor covers.
10. Remove screw holding coat hook to quarter panel. 11. Remove screws holding upper quarter
trim panel to inner quarter panel. 12. Separate upper quarter trim panel from vehicle. 13. Reverse
the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7878
Trim Panel: Service and Repair Lift Gate Trim Panel
Lift Gate Trim Panel
REMOVAL
1. Raise lift gate and remove courtesy lamp lenses. 2. Remove courtesy lamp assemblies. Insert
courtesy lamps through openings in the trim panel into lift gate, if equipped. 3. Remove speaker
grilles, if equipped. 4. Remove plugs at the ends of the assist handle, and remove screws.
Separate handle from trim panel, if equipped. 5. Remove push-in fasteners from above the rear
window. 6. Remove two trim plugs at lower corners of trim panel and remove screws. 7. Disengage
frog-leg fasteners around perimeter of trim panel. Separate trim panel from lift gate.
INSTALLATION
1. Position trim panel under lift gate between the prop-rod cylinders. Insert courtesy lamp
assemblies through trim cover openings. 2. Position frog-leg fasteners below holes in lift gate, one
at a time, push (do not pound) fasteners into locked position. 3. Install assist handle, courtesy
lamps, outer corner attaching screws, speaker grilles and push-in fasteners above rear window.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7879
Trim Panel: Service and Repair Right B-Pillar Trim Cover
Interior Trim
1. Remove cover and bolt holding shoulder harness turning loop to B-pillar. 2. Remove bolt holding
outboard seat belt anchor to floor. 3. Remove A-pillar trim as necessary to gain clearance for
removal of B-pillar trim. 4. Remove door sill scuff plates to gain clearance for removal of B-pillar
trim. 5. Remove screws holding B-pillar trim to B-pillar. 6. Separate B-pillar trim from vehicle 7.
Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7880
Trim Panel: Service and Repair
A-Pillar and Roof Rail Moldings
Interior Trim
1. Remove grab handle, if equipped. 2. Remove windshield side garnish molding. 3. Remove plug
and screw holding A-pillar trim to roof rail. 4. Disengage fasteners holding A-pillar trim to A-pillar. 5.
Separate A-pillar trim from vehicle. 6. Reverse the preceding operation for installation.
Left Quarter Trim Panel
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7881
Quarter Trim Panel
Quarter Trim Panel With Rear A/C
1. Remove ash tray. 2. Remove screw holding quarter trim insert to quarter trim from inside ash
tray opening. 3. Pull outward at bottom of trim insert to disengage clips holding insert to quarter
trim. 4. Lift insert upward and separate quarter trim insert from vehicle. 5. Remove screws holding
lower quarter trim panel to inner quarter panel. 6. Separate lower quarter trim from vehicle. 7.
Remove covers and bolts holding shoulder harness turning loops to upper quarter panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7882
8. Remove bolts holding outboard seat belt anchor to floor. 9. Remove seat belt retractor covers.
10. Remove screw holding coat hook to quarter panel. 11. Remove screws holding upper quarter
trim panel to inner quarter panel. 12. Separate upper quarter trim panel from vehicle. 13. Reverse
the preceding operation for installation.
Lift Gate Trim Panel
Lift Gate Trim Panel
REMOVAL
1. Raise lift gate and remove courtesy lamp lenses. 2. Remove courtesy lamp assemblies. Insert
courtesy lamps through openings in the trim panel into lift gate, if equipped. 3. Remove speaker
grilles, if equipped. 4. Remove plugs at the ends of the assist handle, and remove screws.
Separate handle from trim panel, if equipped. 5. Remove push-in fasteners from above the rear
window. 6. Remove two trim plugs at lower corners of trim panel and remove screws. 7. Disengage
frog-leg fasteners around perimeter of trim panel. Separate trim panel from lift gate.
INSTALLATION
1. Position trim panel under lift gate between the prop-rod cylinders. Insert courtesy lamp
assemblies through trim cover openings. 2. Position frog-leg fasteners below holes in lift gate, one
at a time, push (do not pound) fasteners into locked position. 3. Install assist handle, courtesy
lamps, outer corner attaching screws, speaker grilles and push-in fasteners above rear window.
Right B-Pillar Trim Cover
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7883
Interior Trim
1. Remove cover and bolt holding shoulder harness turning loop to B-pillar. 2. Remove bolt holding
outboard seat belt anchor to floor. 3. Remove A-pillar trim as necessary to gain clearance for
removal of B-pillar trim. 4. Remove door sill scuff plates to gain clearance for removal of B-pillar
trim. 5. Remove screws holding B-pillar trim to B-pillar. 6. Separate B-pillar trim from vehicle 7.
Reverse the preceding operation for installation.
Right Quarter Trim Panel
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7884
Interior Trim
1. Remove lift gate and sliding door sill scuff plate. 2. Remove sliding door upper track cover. 3.
Pull outward at bottom of quarter trim insert to disengage fasteners holding insert to trim panel. 4.
Lift upward on quarter trim insert and separate insert from quarter trim panel. 5. Remove screw
holding coat hook to roof rail and separate hook from vehicle. 6. Remove covers and bolts holding
shoulder harness turning lops to roof rail and separate belts from trim panel. 7. Remove bolts
holding outboard seat belt to floor and separate belt from floor. 8. Remove plugs and screws
holding quarter trim to inner quarter panel. 9. Separate quarter trim panel from vehicle.
10. Reverse the preceding operation for installation.
Upper Track Cover Removal
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar and Roof Rail Moldings > Page 7885
Interior Trim
1. Remove plugs and screws holding upper track cover to sliding door track. 2. Separate track
cover from vehicle. 3. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Customer
Interest for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack
Jack: Customer Interest Body Cladding - Interferes With Use Of Jack
NO: 23-77-94
GROUP: Body
DATE: Oct. 28, 1994
SUBJECT: Body Cladding Interferes With Use Of Jack
MODELS:
1994 - 1995 (AS) Caravan
SYMPTOM/CONDITION:
Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with
the flange of the body cladding on some LE and ES Caravan models.
DIAGNOSIS:
Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional
clearance is needed, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves creating a notch in the body side cladding.
1. Raise the vehicle on an appropriate lifting device.
2. Cut out the template illustrated above.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Customer
Interest for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack > Page 7894
3. Position the template on the bottom flange of the cladding so the notch of the template is
centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the
centers for the two 3/8" holes.
4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8".
5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of
the holes drilled in step 4.
6. Repeat steps 3 through 5 for the other side.
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-38-91 0.4 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack
Jack: All Technical Service Bulletins Body Cladding - Interferes With Use Of Jack
NO: 23-77-94
GROUP: Body
DATE: Oct. 28, 1994
SUBJECT: Body Cladding Interferes With Use Of Jack
MODELS:
1994 - 1995 (AS) Caravan
SYMPTOM/CONDITION:
Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with
the flange of the body cladding on some LE and ES Caravan models.
DIAGNOSIS:
Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional
clearance is needed, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves creating a notch in the body side cladding.
1. Raise the vehicle on an appropriate lifting device.
2. Cut out the template illustrated above.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack > Page 7900
3. Position the template on the bottom flange of the cladding so the notch of the template is
centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the
centers for the two 3/8" holes.
4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8".
5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of
the holes drilled in step 4.
6. Repeat steps 3 through 5 for the other side.
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-02-38-91 0.4 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations > Page 7906
Keyless Entry Module: Diagrams
Remote Keyless Entry Module Connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Service and Repair > Programming Module
Keyless Entry Module: Service and Repair Programming Module
PROGRAMMING RKE MODULE
The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is
interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be
programmed into the Body Control Module (BCM). A functional key fob transmitter is required to
program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan
tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm
(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds
(maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC
button. A single chime will sound to verify that the
RKE module is set to receive the new VAC.
(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30
seconds or when ignition switch is turned OF{ the RKE
module will end the programming mode. A single chime will sound to verify that the RKE module
will no longer receive additional VAC(s).
(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation
using each key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Service and Repair > Programming Module > Page 7909
Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement
REMOVAL
(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.
INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component
Information > Technical Service Bulletins > Remote Keyless Entry - Transmitter Malfunction
Keyless Entry Transmitter: Technical Service Bulletins Remote Keyless Entry - Transmitter
Malfunction
NO.: 08-51-93
GROUP: Electrical
DATE: Oct. 15, 1993
SUBJECT: Remote Keyless Entry System
MODELS:
1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
SYMPTOM/CONDITION:
Some vehicles may require the Remote Keyless Entry (RKE) transmitter button(s) to be repeatedly
depressed to obtain a response from the system.
NOTE: AS-BODY VEHICLES RESPOND DIFFERENTLY TO RKE INPUTS WHEN COMPARED
TO THE SIMILAR SYSTEM USED PREVIOUSLY ON AC/AY-BODY VEHICLES. AS-BODY
VEHICLES HAVE A SHORT DELAY AFTER A RKE TRANSMITTER BUTTON IS DEPRESSED
BEFORE EITHER THE ILLUMINATED ENTRY OR HORN CHIRP IS ACTIVATED. THIS DELAY
IS NORMAL FOR AS-BODY VEHICLES BUT DID NOT OCCUR ON PREVIOUS AC/AY-BODY
VEHICLES.
DIAGNOSIS:
Open the transmitter case to access the batteries. If a white pentastar is NOT readily visible on the
printed circuit board, perform the repair procedure. If the printed circuit board has a white
pentastar, this TSB does not apply and the procedure outlined beginning on page 214 of the Body
Diagnostic Procedures Manual (Publication No. 81- 699-0442) should be used.
PARTS REQUIRED:
2 Transmitter 4469341
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitters.
1. Obtain two new transmitters (P/N 4469341) and verify they have a white pentastar on their
printed circuit boards.
2. Using the procedure outlined on page 8P-5 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105) program the RKE transmitters.
NOTE: IN THE SPIRIT OF CUSTOMER ONE, AND IN CASE THEY WERE NOT TOLD AT THE
TIME OF DELIVERY, THIS WOULD BE AN EXCELLENT TIME TO ADVISE THE CUSTOMER
THE HORN CHIRP FEATURE CAN BE CANCELED WHEN THE NEW RKE TRANSMITTERS
ARE PROGRAMMED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-28-90 0.2 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component
Information > Technical Service Bulletins > Page 7914
Keyless Entry Transmitter: Description and Operation
Normal operation range is up to about a distance of 7 meters (23 ft.) of the vehicle. Range may be
better or worse depending on the environment around the vehicle. Closeness to a radio frequency
transmitter such as a radio station tower may degrade operational range, while range in an open
field will be enhanced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component
Information > Service and Repair > Transmitter Programming
Keyless Entry Transmitter: Service and Repair Transmitter Programming
PROGRAM REMOTE KEYLESS ENTRY
- Open and lower glove box door.
- Locate program line a dark green wire with a molded insulator on the end. Located behind and
lower end of the glove box.
- Turn ignition switch to the ON position.
- Connect the program line from the Remote Keyless Entry Module to ground. the door locks will
lock and unlock to indicate the receiver is ready to receive transmitter code. Liftgate solenoid will
not cycle.
- Press any button on the transmitter to set code. If there is a second transmitter it has to be set at
this time. The locks will cycle to confirm programming.
- Disconnect the program line from ground. This returns the system to its normal operation mode.
- Install glove box to original position.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component
Information > Service and Repair > Transmitter Programming > Page 7917
Keyless Entry Transmitter: Service and Repair Battery Replacement
The batteries can be removed without special tools and are readily available at local retail stores.
The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years.
CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary.
Hands must be clean dry.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Motor <--> [Power Door Lock
Actuator] > Component Information > Service and Repair
Power Door Lock Motor: Service and Repair
1. Remove sliding door latch/lock control assembly. 2. Disconnect linkage rod from power door lock
actuator. 3. Remove screws holding actuator to control. 4. Separate actuator from control.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information
> Locations
Power Door Lock Relay: Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information
> Locations > Page 7925
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions
Mirrors: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 7930
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 7931
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 7932
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 7933
Mirrors: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 7934
Mirrors: Electrical Diagrams
Power Remote Mirrors (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 7935
Power Remote Mirrors (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View
Mirror
Mirrors: Service and Repair Inside Rear View Mirror
Rear View Mirror
1. Using a wax pencil, locate and mark the mounting position of the button on the outside of the
windshield. 2. If the vinyl pad had remained on the windshield glass, apply "low heat" to it with an
electric heat gun until the vinyl softens; then peel the vinyl
pad from the glass.
3. Thoroughly clean the inner surface of the windshield glass in the mounting area of the mirror
button using a mild abrasive cleaning powder such as
Ajax, Comet, or equivalent, on a clean cloth saturated with alcohol. Then, apply alcohol to a paper
towel and wipe off any traces of remaining cleaner.
4. Thoroughly sand the windshield mounting surface (the side with least surface area) of the mirror
button with a clean piece of fine grit sandpaper
and wipe the surface clean with a clean paper towel saturated with alcohol.
5. Using kit 4054099 or equivalent, crush the vial in the plastic housing of the accelerator. This
saturates the felt applicator. Remove paper sleeve.
Apply a generous amount of accelerator on the mounting surface of the mirror button.
6. Allow the accelerator to dry for 5 minutes. Do not touch the mounting surface of the button or
glass. 7. Apply a thin film of Accelerator to the inner surface of the windshield in the button
mounting area. Allow one minute to dry. Do not touch the
surface.
8. Apply one drop of Adhesive to the center of the windshield mounting surface of the mirror button
and, using the bottom of the Adhesive tube,
quickly distribute the adhesive evenly over the entire bonding surface of the button.
9. Position the bottom straight edge of the mirror button on the horizontal line and center it on the
vertical line and press it firmly to the glass and
apply pressure for about one minute. Proper location is essential as cement sets up very fast.
10. Allow five minutes for the adhesive to set; then, remove any excess adhesive residue from the
windshield in the attachment area using an
alcohol-dampened cloth.
11. Slide the mirror downward onto the button and tighten the screw.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View
Mirror > Page 7938
Mirrors: Service and Repair Outside Rear View Mirror
Side View Mirror
1. Remove door trim panel and water shield as necessary to gain access to side view mirror. 2.
Disconnect power side view mirror wire connector, if equipped. 3. Remove nuts holding side view
mirror to door frame. 4. Separate mirror from door.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Body Control Module System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 7943
Keyless Entry Module: Diagrams
Remote Keyless Entry Module Connectors
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair > Programming Module
Keyless Entry Module: Service and Repair Programming Module
PROGRAMMING RKE MODULE
The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is
interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be
programmed into the Body Control Module (BCM). A functional key fob transmitter is required to
program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan
tool (DRB) can be used to program the BCM.
(1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm
(2) Insert ignition key into the ignition switch.
(3) Switch ignition to RUN position without starting engine.
(4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds
(maximum ten seconds).
(5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC
button. A single chime will sound to verify that the
RKE module is set to receive the new VAC.
(6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30
seconds or when ignition switch is turned OF{ the RKE
module will end the programming mode. A single chime will sound to verify that the RKE module
will no longer receive additional VAC(s).
(7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation
using each key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair > Programming Module > Page 7946
Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement
REMOVAL
(1) Remove instrument panel top cover.
(2) Remove screws holding RKE module to instrument panel.
(3) Disconnect wire connector from RKE module.
(4) Remove module.
INSTALLATION
Reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 7950
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Service and Repair
Roof Rack Frame: Service and Repair
NOTE: The luggage rack skid strips are attached to the roof panel with adhesive strips using the
same methods as stick-on body side moldings.
Roof Top Luggage Rack
1. Slide side rail end covers from ends of side rails. 2. Remove screws holding rails to roof panel. 3.
Separate luggage rack from vehicle. 4. Reverse the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins
> Customer Interest for Seat Back: > 232494 > Mar > 94 > Front Seat Back - Squeaking Noise
Seat Back: Customer Interest Front Seat Back - Squeaking Noise
NO: 23-24-94 GROUP: Body DATE: Mar. 11, 1994
SUBJECT: Front Seat Back Squeak Noise
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Front seat squeaks where the seat back meets the seat cushion. The squeak may be experienced
while reclining the seat back or while driving the vehicle. The squeak may be caused by the pivot
bolt.
DIAGNOSIS:
With the seat back in the full upright position, apply fore and aft pressure to the top of the seat
back. If a squeaking noise is heard at the seat back pivot area, perform the repair procedure.
PARTS REQUIRED:
AR 4318084 Mopar Lock Lubricant
REPAIR PROCEDURE:
This bulletin involves lubricating the front seat back pivot bolt.
1. Remove the seat side shield.
2. Apply Mopar Lock Lubricant (P/N 4318084) to the pivot bolt. Use care to prevent soiling the seat
upholstery.
3. Apply fore and aft pressure to the top of the seat back to verify the lubricant has reached the
squeaking area. Reapply lubricant as necessary.
4. Reinstall the seat side shield.
5. Repeat steps 1 through 4 for the other side, if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-20-32-90 0.3 Hrs.
FAILURE CODE: CX - Squeaks
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Back: > 232494 > Mar > 94 > Front Seat Back - Squeaking Noise
Seat Back: All Technical Service Bulletins Front Seat Back - Squeaking Noise
NO: 23-24-94 GROUP: Body DATE: Mar. 11, 1994
SUBJECT: Front Seat Back Squeak Noise
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Front seat squeaks where the seat back meets the seat cushion. The squeak may be experienced
while reclining the seat back or while driving the vehicle. The squeak may be caused by the pivot
bolt.
DIAGNOSIS:
With the seat back in the full upright position, apply fore and aft pressure to the top of the seat
back. If a squeaking noise is heard at the seat back pivot area, perform the repair procedure.
PARTS REQUIRED:
AR 4318084 Mopar Lock Lubricant
REPAIR PROCEDURE:
This bulletin involves lubricating the front seat back pivot bolt.
1. Remove the seat side shield.
2. Apply Mopar Lock Lubricant (P/N 4318084) to the pivot bolt. Use care to prevent soiling the seat
upholstery.
3. Apply fore and aft pressure to the top of the seat back to verify the lubricant has reached the
squeaking area. Reapply lubricant as necessary.
4. Reinstall the seat side shield.
5. Repeat steps 1 through 4 for the other side, if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-20-32-90 0.3 Hrs.
FAILURE CODE: CX - Squeaks
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> Customer Interest: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly
Seat Latch: Customer Interest Front Seat Adjuster Latch - Does Not Latch Smoothly
NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Front Seat Manual Adjuster Latching
NOTE:
THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE
NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS: 1991 - **1994** (AS) Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as
smoothly as the other side.
DIAGNOSIS:
This condition may be noticed after the seat has been adjusted and the adjustment handle is
released. If one side of the adjuster latches while the other side requires the occupant of the seat to
shift their weight in order for it to latch, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the inboard seat riser.
1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure
1.)
2. Remove the seat assembly from the risers and set it outside of the vehicle.
3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and
aft, being careful to not enlarge the hole
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> Customer Interest: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly > Page 7977
side-to-side. (Refer to Figure 2.)
4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position.
Reposition the adjusters as necessary.
5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs.
6. Verify the repair by performing the diagnosis procedure again.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side
(1991-1994) 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly
Seat Latch: All Technical Service Bulletins Front Seat Adjuster Latch - Does Not Latch Smoothly
NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Front Seat Manual Adjuster Latching
NOTE:
THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE
NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS: 1991 - **1994** (AS) Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as
smoothly as the other side.
DIAGNOSIS:
This condition may be noticed after the seat has been adjusted and the adjustment handle is
released. If one side of the adjuster latches while the other side requires the occupant of the seat to
shift their weight in order for it to latch, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the inboard seat riser.
1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure
1.)
2. Remove the seat assembly from the risers and set it outside of the vehicle.
3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and
aft, being careful to not enlarge the hole
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly > Page 7983
side-to-side. (Refer to Figure 2.)
4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position.
Reposition the adjusters as necessary.
5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs.
6. Verify the repair by performing the diagnosis procedure again.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side
(1991-1994) 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Seat Latch: > 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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Seat Latch: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page
7989
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Seat Latch: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page
7995
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Customer Interest for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise
Seat Track: Customer Interest Quad Seat Floor Attachment - Rattling Noise
NO: 23-74-94 Rev. A
GROUP: Body
DATE: Oct. 28, 1994
SUBJECT: Rattling Noise from Quad Seat Floor Attachment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-74-94 DATED OCT. 7,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION INVOLVES
CORRECTION OF A PART NUMBER AND IS HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Rattling noise from quad seat floor attachment when driving over rough roads.
DIAGNOSIS:
Grasp the back of each quad seat and shake fore and aft and side to side. If a rattle is heard,
perform the repair procedure.
PARTS REQUIRED:
4 4705758 Bumper
4 154695 Screw
2 ** 4705760 ** Cap
REPAIR PROCEDURE:
This bulletin involves installing rubber bumpers on the bottom front of the quad seat risers.
1. Unlatch and remove the quad seats from the vehicle.
2. Locate the hole on the bottom side near the front of the quad seat risers and install a rubber
bumper, P/N 4705758, on each riser (Refer to illustration).
3. Thread a screw, P/N 154695, into each bumper and tighten until approximately 3/4 in. of the
screw protrudes through the bumper.
4. On the left side quad seat install cap, P/N 4705760, over the protruding portion of the screws.
5. Install the quad seats and securely latch.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Customer Interest for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise > Page 8004
TIME ALLOWANCE: Labor Operation No:
23-13-37-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Customer Interest for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle
Seat Track: Customer Interest Rear Seat Adjuster - Rattle
NO: 23-37-94
GROUP: Body
DATE: Apr. 22, 1994
SUBJECT: Rear Seat Adjuster Rattle
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT BETWEEN 3/15/94 AND 3/25/94 (MDH
03-15-XX THROUGH 03-25-XX).
SYMPTOM/CONDITION:
Rattle noise from the area of the rear seat left side riser.
DIAGNOSIS:
Inspect the left rear seat adjuster for a mis-positioned adjuster link wire to adjuster latch arm
condition. If this is determined to be the source of the rattle, perform the repair procedure.
PARTS REQUIRED:
1 6503043 Fastener, Push Pin
REPAIR PROCEDURE:
This bulletin involves installing a push pin fastener to prevent a mis-positioned adjuster link wire to
adjuster latch arm condition from reoccurring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Customer Interest for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle > Page 8009
1. While holding the rear seat adjuster handle (from behind the seat) to the released position, insert
the push pin fastener (P/N 6503043) into the slot of the left adjuster latch arm as illustrated.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-13-37-90 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Customer Interest for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly
Seat Track: Customer Interest Front Seat Adjuster Latch - Does Not Latch Smoothly
NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Front Seat Manual Adjuster Latching
NOTE:
THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE
NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS: 1991 - **1994** (AS) Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as
smoothly as the other side.
DIAGNOSIS:
This condition may be noticed after the seat has been adjusted and the adjustment handle is
released. If one side of the adjuster latches while the other side requires the occupant of the seat to
shift their weight in order for it to latch, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the inboard seat riser.
1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure
1.)
2. Remove the seat assembly from the risers and set it outside of the vehicle.
3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and
aft, being careful to not enlarge the hole
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Customer Interest for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly > Page
8014
side-to-side. (Refer to Figure 2.)
4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position.
Reposition the adjusters as necessary.
5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs.
6. Verify the repair by performing the diagnosis procedure again.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side
(1991-1994) 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Customer Interest for Seat Track: > 231194 > Feb > 94 > Rear Seat - High Sliding Effort
Seat Track: Customer Interest Rear Seat - High Sliding Effort
NO: 23-11-94
GROUP: Body
DATE: Feb. 4, 1994
SUBJECT: Rear Seat Sliding Effort
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
Complaints of high effort required to slide the rear bench seat to achieve the desired fore and aft
adjustment may be encountered.
Prior to any parts replacement, slide the rear seat fore and aft through the full range of travel
approximately 15 times. This will burnish the adjuster tracks and reduce the effort required to slide
the bench seat fore and aft.
If the effort required is still unacceptable, lubricate the adjuster slides with Mopar Silicone Spray
Lube, P/N 4318070.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise
Seat Track: All Technical Service Bulletins Quad Seat Floor Attachment - Rattling Noise
NO: 23-74-94 Rev. A
GROUP: Body
DATE: Oct. 28, 1994
SUBJECT: Rattling Noise from Quad Seat Floor Attachment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-74-94 DATED OCT. 7,
1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION INVOLVES
CORRECTION OF A PART NUMBER AND IS HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Rattling noise from quad seat floor attachment when driving over rough roads.
DIAGNOSIS:
Grasp the back of each quad seat and shake fore and aft and side to side. If a rattle is heard,
perform the repair procedure.
PARTS REQUIRED:
4 4705758 Bumper
4 154695 Screw
2 ** 4705760 ** Cap
REPAIR PROCEDURE:
This bulletin involves installing rubber bumpers on the bottom front of the quad seat risers.
1. Unlatch and remove the quad seats from the vehicle.
2. Locate the hole on the bottom side near the front of the quad seat risers and install a rubber
bumper, P/N 4705758, on each riser (Refer to illustration).
3. Thread a screw, P/N 154695, into each bumper and tighten until approximately 3/4 in. of the
screw protrudes through the bumper.
4. On the left side quad seat install cap, P/N 4705760, over the protruding portion of the screws.
5. Install the quad seats and securely latch.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise >
Page 8024
TIME ALLOWANCE: Labor Operation No:
23-13-37-90 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle
Seat Track: All Technical Service Bulletins Rear Seat Adjuster - Rattle
NO: 23-37-94
GROUP: Body
DATE: Apr. 22, 1994
SUBJECT: Rear Seat Adjuster Rattle
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT BETWEEN 3/15/94 AND 3/25/94 (MDH
03-15-XX THROUGH 03-25-XX).
SYMPTOM/CONDITION:
Rattle noise from the area of the rear seat left side riser.
DIAGNOSIS:
Inspect the left rear seat adjuster for a mis-positioned adjuster link wire to adjuster latch arm
condition. If this is determined to be the source of the rattle, perform the repair procedure.
PARTS REQUIRED:
1 6503043 Fastener, Push Pin
REPAIR PROCEDURE:
This bulletin involves installing a push pin fastener to prevent a mis-positioned adjuster link wire to
adjuster latch arm condition from reoccurring.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle > Page 8029
1. While holding the rear seat adjuster handle (from behind the seat) to the released position, insert
the push pin fastener (P/N 6503043) into the slot of the left adjuster latch arm as illustrated.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-13-37-90 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch
Smoothly
Seat Track: All Technical Service Bulletins Front Seat Adjuster Latch - Does Not Latch Smoothly
NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Front Seat Manual Adjuster Latching
NOTE:
THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE
NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**.
MODELS: 1991 - **1994** (AS) Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as
smoothly as the other side.
DIAGNOSIS:
This condition may be noticed after the seat has been adjusted and the adjustment handle is
released. If one side of the adjuster latches while the other side requires the occupant of the seat to
shift their weight in order for it to latch, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves modifying the inboard seat riser.
1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure
1.)
2. Remove the seat assembly from the risers and set it outside of the vehicle.
3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and
aft, being careful to not enlarge the hole
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch
Smoothly > Page 8034
side-to-side. (Refer to Figure 2.)
4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position.
Reposition the adjusters as necessary.
5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs.
6. Verify the repair by performing the diagnosis procedure again.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side
(1991-1994) 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Track: > 231194 > Feb > 94 > Rear Seat - High Sliding Effort
Seat Track: All Technical Service Bulletins Rear Seat - High Sliding Effort
NO: 23-11-94
GROUP: Body
DATE: Feb. 4, 1994
SUBJECT: Rear Seat Sliding Effort
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
Complaints of high effort required to slide the rear bench seat to achieve the desired fore and aft
adjustment may be encountered.
Prior to any parts replacement, slide the rear seat fore and aft through the full range of travel
approximately 15 times. This will burnish the adjuster tracks and reduce the effort required to slide
the bench seat fore and aft.
If the effort required is still unacceptable, lubricate the adjuster slides with Mopar Silicone Spray
Lube, P/N 4318070.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps
Strut / Shock Tower: Customer Interest Front Suspension - Rapping Noise On Bumps
NO: 02-19-94
GROUP: Front Suspension
DATE: Nov. 25, 1994
SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**.
MODELS:
1994 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps.
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s).
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion recommendations.
5. Reinstall the strut assembly(s).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 8051
6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe
adjustment 0.1 degree toe in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 (One Side) 1.4 Hrs.
02-27-01-95 (Both Sides) 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise
Strut / Shock Tower: Customer Interest Front Coil Spring - Metallic Rapping Noise
NO.: 02-08-93
GROUP: Front Suspension
DATE: Oct. 29, 1993
SUBJECT: Noise Due To Coil Spring To Strut Tower Contact
MODELS:
1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country
NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93
(MDH 0820xx).
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s).
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This repair involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the
1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105)
beginning on page 2-8.
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 8056
recommendations.
5. Reinstall the strut assembly(s).
6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3
degrees and toe adjustment 0.1 degree tow in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 One Side 1.4 Hrs.
02-27-01-95 Both Sides 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front Suspension - Rapping
Noise On Bumps
Strut / Shock Tower: All Technical Service Bulletins Front Suspension - Rapping Noise On Bumps
NO: 02-19-94
GROUP: Front Suspension
DATE: Nov. 25, 1994
SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**.
MODELS:
1994 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps.
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This bulletin involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s).
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion recommendations.
5. Reinstall the strut assembly(s).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front Suspension - Rapping
Noise On Bumps > Page 8062
6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe
adjustment 0.1 degree toe in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 (One Side) 1.4 Hrs.
02-27-01-95 (Both Sides) 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose - Squeaking Noise
Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise
NO: 24-02-94
GROUP: Heat & A/C
DATE: Jan. 14, 1994
SUBJECT: Squeak in Right Shock Tower Area
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right
shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in
the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn
through, a squeak may occur under driving conditions. Inspect the hose and bracket area and
relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil Spring - Metallic
Rapping Noise
Strut / Shock Tower: All Technical Service Bulletins Front Coil Spring - Metallic Rapping Noise
NO.: 02-08-93
GROUP: Front Suspension
DATE: Oct. 29, 1993
SUBJECT: Noise Due To Coil Spring To Strut Tower Contact
MODELS:
1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country
NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93
(MDH 0820xx).
SYMPTOM/CONDITION:
A metal to metal rapping noise can be heard coming from the front suspension when traveling over
bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s).
DIAGNOSIS:
With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for
witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If
contact is evident, perform the repair procedure.
REPAIR PROCEDURE:
This repair involves providing additional clearance between the front coil spring(s) and strut
tower(s).
1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the
1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105)
beginning on page 2-8.
2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring
contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against
the sheetmetal of the strut tower, their contours match.
3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6
mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the
reference.
4. Repair the paint of the reworked area both in the wheel well and the engine compartment as
necessary. Use the paint manufacturer anti-corrosion
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil Spring - Metallic
Rapping Noise > Page 8071
recommendations.
5. Reinstall the strut assembly(s).
6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3
degrees and toe adjustment 0.1 degree tow in.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-27-01-94 One Side 1.4 Hrs.
02-27-01-95 Both Sides 1.9 Hrs.
FAILURE CODE: XX - Service Adjustments
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose - Squeaking Noise
Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise
NO: 24-02-94
GROUP: Heat & A/C
DATE: Jan. 14, 1994
SUBJECT: Squeak in Right Shock Tower Area
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right
shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in
the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn
through, a squeak may occur under driving conditions. Inspect the hose and bracket area and
relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
Windshield/Cowl - Squeak Elimination
Cowl: Technical Service Bulletins Windshield/Cowl - Squeak Elimination
NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Squeak Noise At The Base Of The Windshield
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
Water soluble support spacers are used in the windshield installation process at the assembly plant
to properly position the windshield. During the transit and vehicle predelivery processes, if enough
water does not come in contact with the windshield support spacers, they may not dissolve as
intended and may cause a squeaking noise. Typically, enough water contacts the windshield
support spacers during a car wash.
Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the
base of the windshield (refer to the illustration). If the support spacers are still in place, raise the
cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve.
This will prevent the customer from experiencing a squeak condition on the new vehicle.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Front Door Frame Rear Molding
Front Door Weatherstrip: Service and Repair Front Door Frame Rear Molding
Belt Moulding And Weatherstrip
1. Remove belt molding and weatherstrip as necessary to clear door frame molding removal path.
2. Remove glass run weatherstrip to gain access to molding clips. 3. Disengage clips holding door
frame molding to door frame 4. Separate molding from door. 5. Reverse the preceding operation
for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Front Door Frame Rear Molding > Page 8087
Front Door Weatherstrip: Service and Repair Front Door Belt Molding and Weatherstrip
VAN ONLY
Belt Moulding And Weatherstrip
1. Remove door glass. 2. Remove side view mirror. 3. Remove screws holding belt molding and
weatherstrip to door panel. 4. Separate belt molding and weatherstrip from door. 5. Reverse the
preceding operation for installation.
WAGON ONLY
Belt Moulding And Weatherstrip
1. Remove door glass. 2. Remove side view mirror. 3. Remove door glass run weatherstrip. 4.
Disengage clips holding door frame molding to door frame. 5. Remove screws holding belt molding
and weatherstrip to door panel. 6. Separate belt molding and weatherstrip from door. 7. Reverse
the preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component
Information > Service and Repair
Front Door Window Glass Weatherstrip: Service and Repair
Glass Channel And Run Weatherstrip
1. Lower door glass to down position. 2. Remove side view mirror as necessary to gain clearance
for weatherstrip removal. 3. Pull glass run weatherstrip from door frame channel. 4. Reverse the
preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and
Inspection
Brake Switch (Cruise Control): Testing and Inspection
1. Remove stop lamp switch, then inspect for continuity between terminal No. 5 and No. 6 with
plunger released. Continuity Should exist. 2. Inspect for continuity between terminal No. 1 and No.
2 with plunger depressed. Continuity Should exist. 3. Inspect for continuity between terminal No. 3
and No. 4 with plunger depressed. Continuity Should exist. 4. If continuity is not as specified, then
stop lamp switch is out of adjustment or defective.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information >
Description and Operation
Speed Control Servo: Description and Operation
PURPOSE
Actuated by the PCM to obtain and maintain a selected road speed.
Houses the throttle actuator, speed control vacuum solenoid, and speed control vent solenoid.
OPERATION
Power to the solenoids is supplied by the speed control relay.
The Powertrain Control Module (PCM) actuates the vacuum and vent solenoids, by switching the
ground path on and off.
- When the PCM grounds vacuum solenoid, the speed control system opens the throttle to obtain a
selected road speed.
- When the PCM grounds vent solenoid, the speed control system closes the throttle to reduce
road speed.
- The PCM balances the two solenoids to maintain a selected road speed.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information >
Description and Operation > Page 8098
Speed Control Servo: Testing and Inspection
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.
Fig. 72 Servo Harness Connector
3. Disconnect 4-way connector at servo. Pin 2 should read approximately battery voltage. If not,
check for loose connections or repair main harness
as necessary.
4. If voltage reading is satisfactory, check fuse. 5. Disconnect six-way connector from stop lamp
switch, then test pin 3 for battery voltage. If voltage is satisfactory, perform "Stop Lamp Switch
Test."
6. If Stop Lamp Switch test is satisfactory, repair wire between servo and stop lamp switch. 7. If
voltage is not present at pin 3, disconnect four-way speed control connector, then test pin 1 for
battery voltage. 8. If voltage is present, perform "Speed Control Switch Test." 9. If no voltage is
present at pin 1, test pin 2 of the six-way stop lamp switch connector for battery voltage.
10. If voltage is not present, repair wiring as necessary. 11. If speed control switch is satisfactory,
check clockspring for continuity. 12. If clockspring continuity is satisfactory, repair wire between
stop lamp switch and clockspring. 13. If voltage is not present at pin 1 of the four-way speed control
switch connector, check for battery voltage between ignition and fuse. 14. Check continuity
between fuse and clockspring. 15. Connect jumper wire between pin 2 of the four-way connector
and pin 2 of the speed control servo. Pin 1, 3 & 4 of the servo should show battery
voltage.
16. If these terminals do not measure as specified, replace servo. 17. Using an ohmmeter, connect
negative lead to chassis ground, then positive lead to pin 1 of the four-way connector of the main
harness. 18. Ohmmeter should show continuity. If not, repair ground circuit as necessary.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information >
Description and Operation > Page 8099
Speed Control Servo: Service and Repair
1. Remove two nuts attaching speed control 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, then remove clip. 6. Install with throttle in full open position. Align hole in
throttle cable sleeve with hole in servo pin, then install retaining pin. 7. Connect vacuum hose and
electrical connector to servo. 8. Position mounting bracket, then install both screws, attaching
bracket to battery tray. Torque screws to 8.75 ft. lbs. 9. Insert servo studs through holes in throttle
cable and mounting bracket. Install nuts, then torque to 6.6 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair
Cruise Control Servo Cable: Service and Repair
1. Remove air cleaner assembly. 2. Disconnect cable from throttle body by removing retaining clip.
3. Disconnect cable from servo, then remove cable assembly. 4. Locate cable through servo
mounting bracket. 5. Connect cable sleeve to servo stud, align holes, then install clip. 6. Insert
servo studs through holes in cable and holes in bracket, then install nut-washers. 7. Route cable
from servo, through cable support bracket and clip, then install cable end on stud of throttle body.
8. Replace air cleaner.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins
> Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles
Cruise Control Switch: Customer Interest Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins
> Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 8111
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles
Cruise Control Switch: All Technical Service Bulletins Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 8117
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Cruise Control Switch: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt - High
Extension Effort
Seat Belt: All Technical Service Bulletins Middle Bench Seat Outer Seatbelt - High Extension Effort
NO: 23-03-94
GROUP: Body
DATE: Jan. 21, 1994
SUBJECT: Middle Bench Seat Left Seat Belt
MODELS:
1994 (AS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES.
SYMPTOM/CONDITION:
High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to
the stowed position.
DIAGNOSIS:
Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair
procedure.
REPAIR PROCEDURE:
This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel.
1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town &
Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter
trim insert.
2. Remove the silencer material from the back side of the upper quarter trim panel from the area
shown in the illustration.
3. Reverse the procedure in step 1 to reinstall the interior trim.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
23-20-56-91 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins
> Page 8128
Cruise Control Switch: Testing and Inspection
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.
Fig. 108 Speed Control Continuity Chart
Fig. 8 Speed Control Connector Terminal Identification
3. Results should be obtained according to the chart. If these results are not obtained, replace
switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins
> Page 8129
Cruise Control Switch: Service and Repair
1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two
screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting
switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to
install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and
Operation
Cruise Control Vacuum Solenoid: Description and Operation
PURPOSE
Maintain set speed.
Vent vacuum and disable system if there is a brake application or the switch is turned off.
OPERATION
PCM actuates solenoids by applying or removing circuit grounds.
PCM uses various input signals to determine solenoid activation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information >
Description and Operation
Cruise Control Vacuum Vent Solenoid: Description and Operation
PURPOSE
Maintain set speed.
Vent vacuum and disable system if there is a brake application or the switch is turned off.
OPERATION
PCM actuates solenoids by applying or removing circuit grounds.
PCM uses various input signals to determine solenoid activation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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. Remove stop lamp switch, then inspect for continuity between terminal No. 5 and No. 6 with
plunger released. Continuity Should exist. 2. Inspect for continuity between terminal No. 1 and No.
2 with plunger depressed. Continuity Should exist. 3. Inspect for continuity between terminal No. 3
and No. 4 with plunger depressed. Continuity Should exist. 4. If continuity is not as specified, then
stop lamp switch is out of adjustment or defective.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles
Cruise Control Switch: Customer Interest Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles
> Page 8148
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles
Cruise Control Switch: All Technical Service Bulletins Speed Control Switch - Loose/Rattles
NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994
SUBJECT: Speed Control Switch Loose or Rattles
MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit
(AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER
WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR
TO 3/7/94, (MDH 03-07-XX).
SYMPTOM/CONDITION:
Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking
of the speed control switch mounting bosses due to lubricant under the paint and on the metal
mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be
located too far outboard.
PARTS REQUIRED:
1 4565265 Speed Control Switch
2 6032986 Screws
AR NPN Naphtha Cleaning Solvent (Obtain Locally)
REPAIR PROCEDURE:
This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering
wheel mounting surface, top and bottom, and installing a new speed control switch and mounting
screws.
1. Remove the speed control switch from the steering wheel and discard the two mounting screws.
NOTE:
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE
REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE
MANUAL REGARDING AIRBAGS.
2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped),
and speed control wiring as outlined in the appropriate Service Manual.
3. With the steering wheel removed, remove the back cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles > Page 8154
4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using
a 1/4" (6 mm) drill (See Illustration).
5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal
mounting surface. Using a round file or knife, clean out both guide pin holes where the speed
control switch mounts (See Illustration).
6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag,
thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide
pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate.
NOTE:
USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE
EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL
MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH
PLASTIC SURFACES.
7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2.
8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986.
NOTE:
THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS
THEY MAY BE CONTAMINATED WITH LUBRICANT.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs.
FAILURE CODE: BF - Broken
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 220794 > Oct > 94 >
Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left
Cross-Member: All Technical Service Bulletins Crossmember/Alignment/Wheels/Tires - Vehicle
Drifts Left
NO: 22-07-94
GROUP: Tires and Wheels
DATE: Oct. 21, 1994
SUBJECT: Tire Leads/Drifts Left
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11,
1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE
BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING
1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL
REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**.
MODELS:
1991 - **1995** (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift
tendencies.
DIAGNOSIS:
Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to
the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight
drift to the left is expected and normal.
If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following
diagnostic procedures should be followed:
A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected,
return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel
assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is
unchanged, perform step B of the diagnosis.
B. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure.
PARTS REQUIRED:
1 6502553 Screw and Washer Assembly
REPAIR PROCEDURE:
This bulletin involves repositioning the front crossmember.
1. Raise the vehicle on a hoist that leaves the front wheels unsupported.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 220794 > Oct > 94 >
Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 8160
2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame
structure (Refer to the Illustration).
3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment
position of the front crossmember.
4. Loosen the two front and right rear front crossmember attachments.
5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front
crossmember assembly forward using the right rear attachment as the pivot point for the rotation
(looking at the front crossmember from underneath the vehicle, this will be a counterclockwise
rotation). Rotate the crossmember until it contacts the left rear crossmember fastener.
6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is
held against the left rear fastener.
7. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
**8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-00-01-95 (Includes Alignment) 1.0 Hrs.
FAILURE CODE: **LL - Leads Left**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 220794 > Oct > 94 >
Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 8166
2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame
structure (Refer to the Illustration).
3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment
position of the front crossmember.
4. Loosen the two front and right rear front crossmember attachments.
5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front
crossmember assembly forward using the right rear attachment as the pivot point for the rotation
(looking at the front crossmember from underneath the vehicle, this will be a counterclockwise
rotation). Rotate the crossmember until it contacts the left rear crossmember fastener.
6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is
held against the left rear fastener.
7. Check and adjust as necessary, the front alignment to the following preferred specifications:
Camber: 0.3 degree positive
Toe: 0.1 degree in.
**8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
02-00-01-95 (Includes Alignment) 1.0 Hrs.
FAILURE CODE: **LL - Leads Left**
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > Page 8167
Cruise Control Switch: Testing and Inspection
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.
Fig. 108 Speed Control Continuity Chart
Fig. 8 Speed Control Connector Terminal Identification
3. Results should be obtained according to the chart. If these results are not obtained, replace
switch.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > Page 8168
Cruise Control Switch: Service and Repair
1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two
screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting
switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to
install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
8177
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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
8183
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 8192
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 8198
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON
Continuously
ABS Light: Customer Interest ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON
Continuously > Page 8208
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON
Continuously
ABS Light: All Technical Service Bulletins ABS - Warning Light ON Continuously
NO: 05-22-94
GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor
Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The
antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles
brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic
Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair
as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body
harness connector. There should be resistance/interference felt between the male and female
terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic
Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of: 1
4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread
female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and
the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and
spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands
together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON
Continuously > Page 8214
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Technical Service Bulletins > Page 8215
ABS Light: Description and Operation
The ABS warning lamp will normally illuminate for one to two seconds when the ignition switch is
first turned to the On position.
Any time 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 to the On position), it will
activate the ABS warning lamp. When the lamp is on, only the anti-lock function of the brake
system is affected. The base brake system and ability to stop the vehicle will not be affected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Description and Operation
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Locations
Fig. 1
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 8224
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 8225
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 8226
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 8227
Check Gauges Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 8228
Fig. 1
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 8229
Test 12D Repairing The Electro/Mechanical Cluster "NO RESPONSE" Condition
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions
Compass: Technical Service Bulletins Instruments - Calibration/Diagnostics Revisions
NUMBER: 08-78-94
GROUP: Electrical
DATE: Dec. 30, 1994
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**
Models: 1994 Town & Country/Caravan/Voyager - Publication No. 81-370-4105
DESCRIPTION OF CHANGES
Calibration Description & Self Diagnosis
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8234
8C-2
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8235
8C-4
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8236
Compass: Technical Service Bulletins Overhead Compass/Temperature - Manual Revision
NO: 08-78-94
GROUP: Electrical
DATE: Dec. 30, 1994
SUBJECT: Service Manual Revision - Overhead Compass and Temperature
MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager
(European Market)
DISCUSSION:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8237
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8238
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8239
This Technical Service Bulletin contains revised Service Manual pages. The revisions are marked
with **ASTERISKS**.
Please insert the included revised pages in the appropriate Service Manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions
Compass: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8242
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8243
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8244
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8245
Compass: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8246
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8247
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Page 8248
Compass: Description and Operation
Compass Mini-trip Module
PURPOSE:
The compass/mini-trip module is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy, distance to empty (DTE), elapsed time
(ET), and trip odometer (ODO).
OPERATION:
The information needed for the traveler functions is received over the CCD bus from the body
control module.
NOTE: If the compass mini-trip module has been replaced, it may be necessary to reset the
calibration.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Setting Compass Variance
Compass: Adjustments Setting Compass Variance
DEFINITION: Variance is the difference between magnetic north and geographic north. To
determine the variance for the area you are in, refer to the zone map below. The number shown for
your area is the variance number for your area (continued on the following page).
1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold
down both the US/METRIC button and the STEP button for 5 seconds.
NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and
enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number and resume normal operation.
NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can
cause the compass to give false readings.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Setting Compass Variance > Page 8251
Compass: Adjustments Setting the Compass
The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be
displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the
vehicle has gone in three complete circles without stopping, in an area free of magnetic
disturbance.
If the module displays the temperature while the compass is blank, the vehicle must be
demagnetized.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument
Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
DISARMING
1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at
least ten minutes after disconnecting battery ground cable before performing any further repairs on
vehicle. The SRS system is
designed to retain enough voltage to deploy air bag for a short time even after battery has been
disconnected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument
Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8257
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
ARMING
1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side
of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one
is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning
light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate
SRS system is functioning correctly.
5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air
Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information
> Diagrams > Diagram Information and Instructions
Dimmer Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information
> Diagrams > Diagram Information and Instructions > Page 8262
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information
> Diagrams > Diagram Information and Instructions > Page 8263
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information
> Diagrams > Diagram Information and Instructions > Page 8264
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information
> Diagrams > Diagram Information and Instructions > Page 8265
Dimmer Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information
> Diagrams > Diagram Information and Instructions > Page 8266
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Diagrams > Diagram Information and Instructions
Door/Trunk Ajar Indicator/Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Diagrams > Diagram Information and Instructions > Page 8272
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Diagrams > Diagram Information and Instructions > Page 8273
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Diagrams > Diagram Information and Instructions > Page 8274
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Diagrams > Diagram Information and Instructions > Page 8275
Door/Trunk Ajar Indicator/Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Diagrams > Diagram Information and Instructions > Page 8276
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks
Cycle Repeatedly
Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks
Cycle Repeatedly > Page 8285
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly
Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 8291
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Component Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Component Locations > Page 8294
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions
Driver/Vehicle Information Display: Technical Service Bulletins Instruments Calibration/Diagnostics Revisions
NUMBER: 08-78-94
GROUP: Electrical
DATE: Dec. 30, 1994
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**
Models: 1994 Town & Country/Caravan/Voyager - Publication No. 81-370-4105
DESCRIPTION OF CHANGES
Calibration Description & Self Diagnosis
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8299
8C-2
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8300
8C-4
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8303
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8304
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8305
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8306
Driver/Vehicle Information Display: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8307
Warning Lamp Center Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8308
Driver/Vehicle Information Display: Electrical Diagrams
Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8309
Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8310
Warning Lamp Center (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8311
Warning Lamp Center (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Page 8312
Driver/Vehicle Information Display: Service and Repair
1. Remove instrument panel cluster bezel and left panel silencer, then disconnect parking brake
linkage. 2. Remove five cover attaching screws and lower cover, then disconnect all wire
connectors. 3. Remove steering column covers, then remove four cluster screws. 4. On models
with electronic instruments, proceed as follows:
a. Remove four cluster securing screws and four mask housing screws b. Rotate mask down, then
disconnect buttons and PRNDL indicator.
Fig. 9 Mechanical Instrument Cluster Removal
5. On models with mechanical instruments, rotate cluster and disconnect connector. 6. On all
models, remove two transmission indicator screws and cluster. 7. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Service Reminder Indicator Light <-->
[Emissions Maintenance Light] > Component Information > Description and Operation
Service Reminder Indicator Light: Description and Operation
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 Emission Maintenance Reminder (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. After necessary emission maintenance has been performed, connect Diagnosis
Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by
DRB II tool.
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.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Diagram Information and Instructions
Fuel Gauge Sender: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8320
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8321
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8322
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8323
Fuel Gauge Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8324
Fuel Pump System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 8325
Fuel Gauge Sender: Description and Operation
Fuel Pump MODULE And Connector TYPICAL
The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the
tank change.
As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or
further away from, the sensor signal terminal.
The further away the sensor pickup is, the higher the resistance across the sensor is.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 8326
Fuel Gauge Sender: Testing and Inspection
SENDING UNIT TEST
NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check
the gauge -- check for a defective sending unit, sending unit wiring, or body control module.
Sending units and wiring can be checked by grounding the connector leads at the sending unit.
With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to
read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump
module connector.)
The following procedure tests the resistance of the level sensor. It does not test the sensor circuit.
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fluid level changes.
1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the
ground terminal of the fuel pump module connector. (The
middle terminal and the terminal farthest away from the middle terminal.)
2. Move the float lever to the full position and empty position and note the resistance at both points.
3. Replace the sensor if the resistance is not within the specified values.
- Sensor Full Position 8 ohms maximum
- Sensor Empty Position 96.5 - 108.0 ohms
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 8327
Fuel Gauge Sender: Service and Repair
Fuel level sensor replacement procedure is included in Fuel Pump Module service.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
DISARMING
1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at
least ten minutes after disconnecting battery ground cable before performing any further repairs on
vehicle. The SRS system is
designed to retain enough voltage to deploy air bag for a short time even after battery has been
disconnected.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 Disarming > Page 8333
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
ARMING
1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side
of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one
is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning
light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate
SRS system is functioning correctly.
5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air
Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8338
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8339
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8340
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8341
Instrument Panel Circuit Board: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8342
Instrument Panel Circuit Board: Electrical Diagrams
Mechanical Cluster Printed Circuit Board
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8343
Printed Circuit Board Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Locations
Malfunction Indicator Lamp: Locations
NOTE: MIL previously called Check Engine Lamp (CEL).
Light in instrument panel.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Locations > Page 8347
Malfunction Indicator Lamp: Description and Operation
NOTE: Malfunction Indicator Lamp (MIL), previously called Check Engine Lamp (CEL). PURPOSE
Indicates immediate service of engine control system is required.
Informs driver that he has entered "Limp-In" mode, lamp ON while vehicle is being driven.
Displays Diagnostic Trouble Codes (DTC's), stored in memory.
OPERATION
Illuminates for three seconds when ignition switch is turned ON, (for bulb test).
Illuminates if Powertrain Control Module (PCM) receives an out of range input from a monitored
circuit, or, (for vehicles with California emissions), from an emission related device.
- Signals that can set Malfunction Indicator Lamp are battery voltage input, charging system,
Manifold Absolute Pressure (MAP), sensor, Throttle Position Sensor (TPS), Engine Coolant
Temperature (ECT) sensor.
Can be used to display any DTC's stored in memory, SEE POWERTRAIN
MANAGEMENT/COMPUTERS AND CONTROL SYSTEMS/TESTING AND INSPECTION.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8356
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8357
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8358
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8359
Oil Pressure Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 8360
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision
Outside Temperature Display: Technical Service Bulletins Overhead Compass/Temperature Manual Revision
NO: 08-78-94
GROUP: Electrical
DATE: Dec. 30, 1994
SUBJECT: Service Manual Revision - Overhead Compass and Temperature
MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager
(European Market)
DISCUSSION:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision > Page 8365
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision > Page 8366
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision > Page 8367
This Technical Service Bulletin contains revised Service Manual pages. The revisions are marked
with **ASTERISKS**.
Please insert the included revised pages in the appropriate Service Manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module:
> 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Speedometer Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module:
> 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8377
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module:
> 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8378
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Speedometer Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo.
Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8384
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8385
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions
Dimmer Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8391
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8392
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8393
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8394
Dimmer Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8395
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr
> 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr
> 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8404
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: >
082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: >
082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8410
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Locations > Component Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Locations > Component Locations > Page 8413
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions
Fuel Gauge Sender: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8418
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8419
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8420
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8421
Fuel Gauge Sender: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8422
Fuel Pump System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Page 8423
Fuel Gauge Sender: Description and Operation
Fuel Pump MODULE And Connector TYPICAL
The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the
tank change.
As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or
further away from, the sensor signal terminal.
The further away the sensor pickup is, the higher the resistance across the sensor is.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Page 8424
Fuel Gauge Sender: Testing and Inspection
SENDING UNIT TEST
NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check
the gauge -- check for a defective sending unit, sending unit wiring, or body control module.
Sending units and wiring can be checked by grounding the connector leads at the sending unit.
With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to
read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump
module connector.)
The following procedure tests the resistance of the level sensor. It does not test the sensor circuit.
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fluid level changes.
1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the
ground terminal of the fuel pump module connector. (The
middle terminal and the terminal farthest away from the middle terminal.)
2. Move the float lever to the full position and empty position and note the resistance at both points.
3. Replace the sensor if the resistance is not within the specified values.
- Sensor Full Position 8 ohms maximum
- Sensor Empty Position 96.5 - 108.0 ohms
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams > Page 8425
Fuel Gauge Sender: Service and Repair
Fuel level sensor replacement procedure is included in Fuel Pump Module service.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection
Speedometer Head: Testing and Inspection
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and
Inspection
To diagnose and test gauge cluster, a DRB tester (scan tool) must be used. Refer to the DRB
user's manual for diagnostic procedures.
This vehicle is equipped with an electronically driven speedometer and odometer which has the
same appearance as a conventional cable driven unit. The speedometer cable is replaced by a
transmission mounted speed sensor. For diagnosis of the speed sensor refer to: Transmission and
Drivetrain / Transmission Control Systems / Transmission Speed Sensor. See: Powertrain
Management/Transmission Control Systems/Sensors and Switches - Transmission and
Drivetrain/Sensors and Switches - A/T/Transmission Speed Sensor/Testing and Inspection
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component
Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates
Speedometer Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component
Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8437
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component
Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8438
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates
Speedometer Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo.
Fluctuates
NO: 08-07-94 Rev. B
GROUP: Electrical
DATE: Dec. 16, 1994
SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED
OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION
CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO
THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE
MARKED WITH **ASTERISKS**.
MODELS:
1993 - 1995 (AS) Town & Country/Caravan/Voyager
1993 - 1995 (ES) Chrysler Voyager (European Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A
3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.**
SYMPTOM/CONDITION:
**The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh
1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug
wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may
fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms
can be the result of induced voltage between the spark plug wires and the output speed sensor
wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and
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 before
proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not
corrected after repair of any or all DTC'S, continue the diagnosis as follows:
If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output
Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes
fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle
to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**.
If the output speed sensor display does not remain at zero, perform the repair procedure.
If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II
only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear
and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO
MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST
FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero,
perform the repair procedure.
PARTS REQUIRED:
1 6004514 Clip Strap
AR 6015756 Tie Strap
AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll)
AR 4688708 Aluminum Tape (1 in. x 60 yd. roll)
REPAIR PROCEDURE:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8444
This procedure involves covering the wiring harness near the spark plug wires with aluminum tape
to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that
connects to the Transmission Control Module (TCM).
1. Remove and discard the tie strap holding the wiring harness to the right engine mount.
2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On
some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped,
remove and discard the tie strap.
3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the
wiring harness or otherwise damage the clip.
4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25%
overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the
right engine mount.
**NOTE:
THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.**
5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138.
**Triple wrap the harness in the area of the A/C compressor high pressure relief valve.**
6. Re-install the wiring harness and clip at the dip stick.
7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the
wiring clip and through the outboard horizontal hole in the engine mount bracket.
8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator
bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark
plug separator bracket, replace the tie strap.
**9. Position the spark plug cables to provide the maximum distance away from the transmission
wiring harness.**
10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values.
NOTE:
IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN
**18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-90-66-98 0.3 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94
> A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8445
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions > Page 8451
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions > Page 8452
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions > Page 8453
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions > Page 8454
Temperature Sensor (Gauge): Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions > Page 8455
Engine Oil Pressure & Temp. System With Transmission Control
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Page 8456
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.
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and
Inspection
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Relay > Component
Information > Locations
Backup Lamp Relay: Locations
In Power Distribution Center
The Backup Lamp Relay is located in the Power Distribution Box.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Relay > Component
Information > Locations > Page 8462
Power Distribution Center
As shown, the Backup Lamp Relay is in the bottom row center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Relay > Component
Information > Locations > Page 8463
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component
Information > Diagrams > Diagram Information and Instructions
Backup Lamp Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8468
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8469
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8470
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8471
Backup Lamp Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Technical Service Bulletins > Stop Light Switch - Wiring Connector Service
Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service
NO.: 08-67-93
GROUP: Electrical
DATE: Dec. 31, 1993
SUBJECT: Stop Light Switch Wiring Connector Service
MODELS:
1995 (PL) Neon
1994 (AA) Spirit/Acclaim/LeBaron Sedan
1994 (AJ) LeBaron Convertible
1994 (AP) Shadow/Sundance
1994 (AS) Caravan/Voyager/Town & Country
1994 (BR) Ram Pickup
1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
1994 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
When servicing the stop light switch or wiring connector, the stop light switch wiring connector may
be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage
the insulator wedge or the switch itself.
REPAIR PROCEDURE:
This bulletin involves removing the stop light switch with wiring connector attached as an assembly
before disconnecting the wiring connector.
1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the
switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket.
2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring
connector from the stop light switch insulator, Figure 1.
NOTE:
DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING
ON THE WIRING MAY RESULT IN OPEN CIRCUITS.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Technical Service Bulletins > Stop Light Switch - Wiring Connector Service > Page 8476
3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector
insulator and the wedge and prying up while pushing the wedge out towards the wire harness,
Figure 2.
4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge
into the connector, then insert the wiring harness connector into the stop light switch assembly and
finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the
switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the
adjustment procedure in the appropriate service manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Technical Service Bulletins > Page 8477
Stop Lamp Switch: Locations
Brake Switch
Sensor mounted on brake pedal support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Diagram Information and Instructions
Stop Lamp Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Diagram Information and Instructions > Page 8480
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Diagram Information and Instructions > Page 8481
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Diagram Information and Instructions > Page 8482
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Diagram Information and Instructions > Page 8483
Stop Lamp Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Diagram Information and Instructions > Page 8484
Stop Lamp Switch: Electrical Diagrams
Vehicle Speed Control & Stop Lamp Switch SH-57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Diagram Information and Instructions > Page 8485
Vehicle Speed Control & Stop Lamp Switch SH-58
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information >
Diagrams > Page 8486
Stop Lamp Switch: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then
remove switch assembly. 3. Reverse procedure to install. If switch adjustment required, proceed as
follows:
a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull brake
pedal back until it will go back no further. Switch will ratchet backward into correct position.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] >
Component Information > Diagrams > Diagram Information and Instructions
Center High Mounted Stop Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] >
Component Information > Diagrams > Diagram Information and Instructions > Page 8491
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] >
Component Information > Diagrams > Diagram Information and Instructions > Page 8492
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] >
Component Information > Diagrams > Diagram Information and Instructions > Page 8493
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] >
Component Information > Diagrams > Diagram Information and Instructions > Page 8494
Center High Mounted Stop Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] >
Component Information > Diagrams > Diagram Information and Instructions > Page 8495
Center High Mounted Stop Lamp
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams >
Diagram Information and Instructions
Console Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 8501
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 8502
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 8503
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 8504
Console Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 8505
Console Lamp: Electrical Diagrams
Headlamp Switch Controlled Interior & Console Lamps (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 8506
Headlamp Switch Controlled Interior & Console Lamps (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions
Daytime Running Lamp Control Unit: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions > Page 8513
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions > Page 8514
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions > Page 8515
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions > Page 8516
Daytime Running Lamp Control Unit: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions > Page 8517
Daytime Running Lamp Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions > Page 8518
Daytime Running Lamp Control Unit: Electrical Diagrams
Daytime Running Lamp Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Diagrams > Diagram Information and Instructions > Page 8519
Fog Lamp System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram
Information and Instructions
Dimmer Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 8524
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 8525
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 8526
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 8527
Dimmer Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 8528
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Dome Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8533
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8534
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8535
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8536
Dome Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8537
Dome Lamp: Connector Views
Dome To Instrument Panel Wiring
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8538
Instrument Panel To Dome Wiring
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8539
Dome Lamp: Electrical Diagrams
Dome And Courtesy Lamps (Part 1 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8540
Dome And Courtesy Lamps (Part 2 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8541
Dome And Courtesy Lamps (Part 3 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8542
Dome And Courtesy Lamps (Part 4 Of 4)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins >
Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins >
Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8551
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8557
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor
Evaporator Drain Tube: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor
NO: 24-06-95 Rev. A
GROUP: Heater & A/C
DATE: May 26, 1995
SUBJECT: Air Conditioning Ducts Emit Odor
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION
NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**.
MODELS: 1994 - 1995
(AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX)
1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX)
1993 - 1995 (AN) Dakota
1992 - 1995 (AS) Caravan/Voyager/Town & Country
1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH
01-31-XX)
1994 - 1995 (BR) Ram Truck
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision
1995 (PL) Neon
1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer
SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts.
The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related
odors are possible, and are covered separately below:
CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some
vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an
excessive amount of corrosion protection coating being applied on the evaporator external
surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins
become wet from condensation. A new coating has been developed to correct this condition. The
evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A.
CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive
odors from air conditioners can sometimes occur in vehicles that have been in extended use
resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely
to occur in vehicles that have been in extended use in humid climates. To correct this condition, the
internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair
Procedure B.
PARTS AND EQUIPMENT REQUIRED:
REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR
4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993)
AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992)
AR 4798624 Coil, A/C Evaporator (AN 1993-1995)
AR 4723069 Coil, A/C Evaporator (AS 1992)
AR 4734292 Coil, A/C Evaporator (AS 1993-1994)
AR 4797131 Coil, A/C Evaporator (AS 1995)
AR 4723518 Coil, A/C Evaporator (BR 1994)
AR 4798705 Coil, A/C Evaporator (BR 1995)
AR 4644790 Coil, A/C Evaporator (JA 1995)
AR 4797129 Coil, A/C Evaporator (LH 1993-1995)
AR 4797130 Coil, A/C Evaporator (PL 1995)
AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994)
AR 4798705 Coil, A/C Evaporator (ZJ 1995)
REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1
4728942 A/C Evaporator Cleaner
1 4740319 Reusable Applicator
1 NPN Pair of Rubber Gloves
1 NPN Pair of Safety Glasses
REPAIR PROCEDURE A:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8563
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8564
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8570
This repair involves checking the A/C condensation drain tube for proper operation and replacing
the A/C evaporator coil. 1.
Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as
necessary.
2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts
and Equipment Required section. Follow all evaporator removal and replacement instructions listed
in the appropriate vehicle Service Manual.
REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper
operation and cleaning and disinfecting the A/C evaporator coil and housing.
1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair
as necessary.
NOTE:
FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR
CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE
WATER TO FLUSH EYES IF NECESSARY
2. Protect the interior of the vehicle with a drop cloth.
3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C
COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle
for 60 minutes to dry out the evaporator coil.
NOTE:
FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE
THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM.
4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air
velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the
dash panel). Open the vehicle doors. On AS Body models, remove the resistor block.
NOTE:
ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK
ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK
WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE
AND COME OUT.
6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air
supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319.
7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty.
Spray into the resistor block opening on "AS" models.
8. Turn the vehicle OFF and allow to soak for at least 30 minutes.
9. Wipe off any excess cleaner from around the instrument panel ducts.
10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR
OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle
for 20 minutes to dry the system.
NOTE:
FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE
ODOR PROBLEM.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
24-65-02-95 Evaporator, Replace
1994 (AB) 2.7 Hrs.
1995 (AB) 1.9 Hrs.
1992-93 (AC/AY) 2.0 Hrs.
1993-95 (AN) 2.2 Hrs.
1992-93 (AS) 2.4 Hrs.
1994-95 (AS) 3.8 Hrs.
1994-95 (BR) 3.3 Hrs.
**1995 (JA) 3.7 Hrs.**
1993 (LH) 4.1 Hrs.
1994-95 (LH) 3.4 Hrs.
1995 (PL) 3.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8571
1993-95 (ZJ) 3.1 Hrs.
Optional Equipment 24-65-02-60 Console Equipped
1992-93 (AS) 0.2 Hrs.
1993-95 (LH) 0.2 Hrs.
24-65-02-66 50/50 Bench Seat
1993-95 (LH) 0.8 Hrs.
FAILURE CODE: P8 - New Part
**24-65-02-94** Evaporator, Clean and
Disinfect 0.7 Hrs.
FAILURE CODE: YP - Odor
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component
Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component
Locations > Page 8574
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Fog Lamp <--> [Fog/Driving Lamp] > Fog/Driving Lamp Relay >
Component Information > Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component
Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 8587
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 8588
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 8589
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 8590
Hazard Warning Flasher: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 8591
Stop/Turn & Hazard Flasher Systems
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions
Headlight Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions > Page 8600
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions > Page 8601
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions > Page 8602
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions > Page 8603
Headlight Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions > Page 8604
Headlight Switch: Connector Views
Headlamp Switch Connector (Part 1 Of 3)
Headlamp Switch Connector (Part 2 Of 3)
Headlamp Switch Connector (Part 3 Of 3)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions > Page 8605
Headlight Switch: Electrical Diagrams
Headlamp Switch (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Diagram Information and Instructions > Page 8606
Headlamp Switch (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Page 8607
Headlight Switch: Service and Repair
The headlamp switch is part of the left pod switch assembly. 1. Fabricate a 3/16 inch diameter
metal rod approximately 10 inches long. Bend 1 1/2 inches on both ends 90°. 2. Place fabricated
tool in hole right of switch in cluster bezel below the pod switch assembly, then depress lower tab
and pull switch free of lower
tab.
3. Move tool upward right side of switch to top tab, then pull tab down and pull switch out of bezel.
4. Disconnect wire connector. 5. To install, connect wire connector and push switch into until tabs
lock.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Key Cylinder Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8622
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8623
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8624
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8625
Key Cylinder Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8626
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information >
Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations
Backup Lamp Relay: Locations
In Power Distribution Center
The Backup Lamp Relay is located in the Power Distribution Box.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 8635
Power Distribution Center
As shown, the Backup Lamp Relay is in the bottom row center.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 8636
Power Distribution Center
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions
Daytime Running Lamp Control Unit: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8642
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8643
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8644
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8645
Daytime Running Lamp Control Unit: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8646
Daytime Running Lamp Module Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8647
Daytime Running Lamp Control Unit: Electrical Diagrams
Daytime Running Lamp Module
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8648
Fog Lamp System
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Micro Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations
Turn Signal Relay: Locations
Relay Block
Combination flasher relay plugs into the lower left corner of the relay bank located to the left of the
fuse block. Remove the lower steering wheel column cover for access.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8672
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8673
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8674
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8675
Backup Lamp Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service
Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service
NO.: 08-67-93
GROUP: Electrical
DATE: Dec. 31, 1993
SUBJECT: Stop Light Switch Wiring Connector Service
MODELS:
1995 (PL) Neon
1994 (AA) Spirit/Acclaim/LeBaron Sedan
1994 (AJ) LeBaron Convertible
1994 (AP) Shadow/Sundance
1994 (AS) Caravan/Voyager/Town & Country
1994 (BR) Ram Pickup
1994 (LH) Concorde/Intrepid/Vision
1994 (LH) LHS/New Yorker
1994 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
When servicing the stop light switch or wiring connector, the stop light switch wiring connector may
be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage
the insulator wedge or the switch itself.
REPAIR PROCEDURE:
This bulletin involves removing the stop light switch with wiring connector attached as an assembly
before disconnecting the wiring connector.
1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the
switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket.
2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring
connector from the stop light switch insulator, Figure 1.
NOTE:
DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING
ON THE WIRING MAY RESULT IN OPEN CIRCUITS.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service
> Page 8680
3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector
insulator and the wedge and prying up while pushing the wedge out towards the wire harness,
Figure 2.
4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge
into the connector, then insert the wiring harness connector into the stop light switch assembly and
finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the
switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the
adjustment procedure in the appropriate service manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Technical Service Bulletins > Page 8681
Stop Lamp Switch: Locations
Brake Switch
Sensor mounted on brake pedal support bracket.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions
Stop Lamp Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8684
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8685
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8686
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8687
Stop Lamp Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8688
Stop Lamp Switch: Electrical Diagrams
Vehicle Speed Control & Stop Lamp Switch SH-57
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8689
Vehicle Speed Control & Stop Lamp Switch SH-58
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <-->
[Brake Light Switch] > Component Information > Diagrams > Page 8690
Stop Lamp Switch: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then
remove switch assembly. 3. Reverse procedure to install. If switch adjustment required, proceed as
follows:
a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull brake
pedal back until it will go back no further. Switch will ratchet backward into correct position.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Service and Repair
Combination Switch: Service and Repair
The multi-function switch includes the turn signal, headlight beam select and windshield wiper
switches. If any of these switches are found defective, the entire multi-function switch must be
replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3.
On all models, remove upper and lower steering column covers, then remove multi-function switch
tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then
remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly
Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 8702
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar
Lamp - Flickers/Locks Cycle Repeatedly
Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly
NO: 08-21-94
GROUP: Electrical
DATE: Apr. 29, 1994
SUBJECT: Sliding Door Ajar Switch/Adjustment
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17,
1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT
ADDS PARTS AND A REPAIR PROCEDURE.
MODELS:
1991 - 1994 (AS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is
enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be
experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur.
NOTE:
THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE
TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM
THE BODY C-PILLAR.
PARTS REQUIRED:
1 4687558 Switch, Ajar Sliding Door
1 4688479 Bumper, Over-Slam
REPAIR PROCEDURE:
This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door
ajar switch.
1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-4105), remove the sliding door assembly.
2. Cut out the template as shown.
3. Position the template over the sliding door ajar switch and center punch the point indicated on
the template.
4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm)
hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper
may not be able to engage the sheetmetal and be retained.
5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16
mm). Applying silicone the tip of the over-slam
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar
Lamp - Flickers/Locks Cycle Repeatedly > Page 8708
bumper will ease the installation effort.
6. Re-install the sliding door and adjust as necessary.
7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring.
8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the
switch into the C-Pillar cavity.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-80-88-91 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Component Locations
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Component Locations > Page 8711
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions
Headlight Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8719
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8720
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8721
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8722
Headlight Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8723
Headlight Switch: Connector Views
Headlamp Switch Connector (Part 1 Of 3)
Headlamp Switch Connector (Part 2 Of 3)
Headlamp Switch Connector (Part 3 Of 3)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8724
Headlight Switch: Electrical Diagrams
Headlamp Switch (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8725
Headlamp Switch (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 8726
Headlight Switch: Service and Repair
The headlamp switch is part of the left pod switch assembly. 1. Fabricate a 3/16 inch diameter
metal rod approximately 10 inches long. Bend 1 1/2 inches on both ends 90°. 2. Place fabricated
tool in hole right of switch in cluster bezel below the pod switch assembly, then depress lower tab
and pull switch free of lower
tab.
3. Move tool upward right side of switch to top tab, then pull tab down and pull switch out of bezel.
4. Disconnect wire connector. 5. To install, connect wire connector and push switch into until tabs
lock.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service
and Repair
Combination Switch: Service and Repair
The multi-function switch includes the turn signal, headlight beam select and windshield wiper
switches. If any of these switches are found defective, the entire multi-function switch must be
replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3.
On all models, remove upper and lower steering column covers, then remove multi-function switch
tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then
remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations
Turn Signal Relay: Locations
Relay Block
Combination flasher relay plugs into the lower left corner of the relay bank located to the left of the
fuse block. Remove the lower steering wheel column cover for access.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Underhood Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8741
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8742
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8743
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8744
Underhood Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8745
Underhood Lamp
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Vanity Lamp: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8750
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8751
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8752
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8753
Vanity Lamp: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8754
Vanity Lamp: Electrical Diagrams
Overhead Console W/O Mini-Trip Computer (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8755
Overhead Console W/O Mini-Trip Computer (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass
Element Relay > Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Relay Block
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Diagram Information and Instructions
Power Window Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8770
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8771
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8772
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8773
Power Window Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8774
Power Window Switch: Electrical Diagrams
Overhead Console W/O Mini-Trip Computer (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 8775
Overhead Console W/O Mini-Trip Computer (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Diagrams > Diagram Information and Instructions
Power Window Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8781
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8782
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8783
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8784
Power Window Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8785
Power Window Switch: Electrical Diagrams
Overhead Console W/O Mini-Trip Computer (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8786
Overhead Console W/O Mini-Trip Computer (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door
Window Glass Weatherstrip > Component Information > Service and Repair
Front Door Window Glass Weatherstrip: Service and Repair
Glass Channel And Run Weatherstrip
1. Lower door glass to down position. 2. Remove side view mirror as necessary to gain clearance
for weatherstrip removal. 3. Pull glass run weatherstrip from door frame channel. 4. Reverse the
preceding operation for installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
Front Door Power 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. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
3. Remove the mounting bolts holding the manual regulator to the inner door panel.
4. Disengage the push-in fastener holding the regulator cables to the inner door panel.
5. Remove the manual window regulator from the door.
INSTALLATION
1. Install the manual window regulator into the door.
2. Install the push-in fastener holding the regulator cables to the inner door panel.
3. Install the mounting bolts that hold the manual regulator to the inner door panel.
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Manual Window Regulator Replacement > Page 8796
Window Regulator: Service and Repair Power Window Regulator Replacement
*** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-29-93 DATED JUNE 4, 1993
Front Door Power 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. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
3. Disconnect the battery negative cable.
4. Disconnect the power window motor electrical connector. Disengage push-in fastener holding
regulator wiring harness to inner door panel.
5. Remove the mounting bolts holding the power regulator to the inner door panel.
6. Disengage the push-in fastener holding the regulator cables to the inner door panel.
5. Remove the power window regulator from the door.
INSTALLATION
1. Install the power window regulator into the door.
2. Install the push-in fastener holding the regulator cables to the inner door panel.
3. Install the mounting bolts that hold the power regulator to the inner door panel.
4. Connect the power window motor electrical connector and the fastener that holds the wiring
harness to the inner door panel.
5. Connect the negative battery terminal.
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and
Repair
Window Track: Service and Repair
Front Door Glass Lower Channel Removal
Front Lower Channel And Window Regulator
1. Remove door trim panel and water shield. 2. Raise glass to up position. 3. Remove bolts holding
channel to inner door panel. 4. Separate channel from door. 3. Reverse the preceding operation for
installation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Customer Interest: > 236894 > Sep > 94 > Backlight/Windshield Moulding - Glue Oozing Out
Windshield: Customer Interest Backlight/Windshield Moulding - Glue Oozing Out
NO: 23-68-94
GROUP: Body
DATE: Sep. 30, 1994
SUBJECT: Glue Oozes Out at Backlight or Windshield Molding
MODELS:
1994 - 1995 (AN) Dakota
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1995 (BR) Ram Truck
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 (JA) Cirrus/Stratus
1994 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
1995 (PL) Neon
SYMPTOM/CONDITION:
A sticky clear to light brown material (hot melt glue) seeps out of the edge of the backlight and/or
windshield molding and collects at the bottom corners of the moldings. The material could also be
seeping into the trunk drain trough. The hot melt glue is used as an aid during vehicle assembly
and has no effect on the structural or sealing integrity of the vehicle. After a period of time the hot
melt glue reacts with the backlight and/or windshield moldings and causes the hot melt glue to melt
at a lower temperature thus running down the sides of the glass to the bottom of the molding.
DIAGNOSIS:
Visually inspect the lower corners of the backlight and windshield moldings. If the hot melt glue is
visible, perform the repair procedure.
PARTS REQUIRED:
AR 4318067 Solvent, Mopar Concentrated Windshield Washer
REPAIR PROCEDURE:
This bulletin involves removal of the hot melt glue from the backlight and/or windshield glass and
molding.
1. Clean up of the glue is accomplished with Mopar Concentrated Windshield Washer Solvent, P/N
4318067. The washer solvent is an alcohol based material and dissolves the glue for easy clean up
with a cloth.
2. Use a trim stick or tongue depressor covered with a cloth saturated with windshield washer
concentrate to get under the molding and run along the edge of the glass to remove as much of the
hot melt glue as possible. If most of the glue is not removed, the condition will reoccur.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-30-50-92 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Windshield: > 236894 > Sep > 94 > Backlight/Windshield Moulding - Glue Oozing Out
Windshield: All Technical Service Bulletins Backlight/Windshield Moulding - Glue Oozing Out
NO: 23-68-94
GROUP: Body
DATE: Sep. 30, 1994
SUBJECT: Glue Oozes Out at Backlight or Windshield Molding
MODELS:
1994 - 1995 (AN) Dakota
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1995 (BR) Ram Truck
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 (JA) Cirrus/Stratus
1994 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
1995 (PL) Neon
SYMPTOM/CONDITION:
A sticky clear to light brown material (hot melt glue) seeps out of the edge of the backlight and/or
windshield molding and collects at the bottom corners of the moldings. The material could also be
seeping into the trunk drain trough. The hot melt glue is used as an aid during vehicle assembly
and has no effect on the structural or sealing integrity of the vehicle. After a period of time the hot
melt glue reacts with the backlight and/or windshield moldings and causes the hot melt glue to melt
at a lower temperature thus running down the sides of the glass to the bottom of the molding.
DIAGNOSIS:
Visually inspect the lower corners of the backlight and windshield moldings. If the hot melt glue is
visible, perform the repair procedure.
PARTS REQUIRED:
AR 4318067 Solvent, Mopar Concentrated Windshield Washer
REPAIR PROCEDURE:
This bulletin involves removal of the hot melt glue from the backlight and/or windshield glass and
molding.
1. Clean up of the glue is accomplished with Mopar Concentrated Windshield Washer Solvent, P/N
4318067. The washer solvent is an alcohol based material and dissolves the glue for easy clean up
with a cloth.
2. Use a trim stick or tongue depressor covered with a cloth saturated with windshield washer
concentrate to get under the molding and run along the edge of the glass to remove as much of the
hot melt glue as possible. If most of the glue is not removed, the condition will reoccur.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
23-30-50-92 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Windshield: > 232794 > Mar > 94 > Windshield/Cowl - Squeak Elimination
Windshield: All Technical Service Bulletins Windshield/Cowl - Squeak Elimination
NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Squeak Noise At The Base Of The Windshield
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
Water soluble support spacers are used in the windshield installation process at the assembly plant
to properly position the windshield. During the transit and vehicle predelivery processes, if enough
water does not come in contact with the windshield support spacers, they may not dissolve as
intended and may cause a squeaking noise. Typically, enough water contacts the windshield
support spacers during a car wash.
Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the
base of the windshield (refer to the illustration). If the support spacers are still in place, raise the
cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve.
This will prevent the customer from experiencing a squeak condition on the new vehicle.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Windshield: > 232794 > Mar > 94 > Windshield/Cowl - Squeak Elimination
Windshield: All Technical Service Bulletins Windshield/Cowl - Squeak Elimination
NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994
SUBJECT: Squeak Noise At The Base Of The Windshield
MODELS: 1994 (AS) Town & Country/Caravan/Voyager
DISCUSSION:
Water soluble support spacers are used in the windshield installation process at the assembly plant
to properly position the windshield. During the transit and vehicle predelivery processes, if enough
water does not come in contact with the windshield support spacers, they may not dissolve as
intended and may cause a squeaking noise. Typically, enough water contacts the windshield
support spacers during a car wash.
Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the
base of the windshield (refer to the illustration). If the support spacers are still in place, raise the
cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve.
This will prevent the customer from experiencing a squeak condition on the new vehicle.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions
Washer Fluid Level Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8828
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8829
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8830
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8831
Washer Fluid Level Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8832
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8833
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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
The multi-function switch includes the turn signal, headlight beam select and windshield wiper
switches. If any of these switches are found defective, the entire multi-function switch must be
replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3.
On all models, remove upper and lower steering column covers, then remove multi-function switch
tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then
remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams
Wiper Switch: Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 8840
Rear Wiper Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 8841
Wiper Switch: Testing and Inspection
1. Place pod switch in the Off position.
Intermittent Wiper Pod Switch
2. Check for continuity between terminals A6 and A4. If continuity is not indicated, replace switch.
3. Place pod switch in the Max Delay position (left end of variable resistor). 4. Check for continuity
between terminal A7 and terminals A5, A3 and B3. If continuity is not indicated, replace pod switch.
5. Check resistance between terminals A1 and B3. Resistance should measure 210,000-390,000
ohms. If not, replace the pod switch. 6. Place switch in the Min Delay position (right end of variable
resistor). 7. Check for continuity between terminal A7 and terminals A5, A3 and B3. 8. Check
resistance between terminals A1 and B3. Resistance should measure 350-650 ohms. 9. When the
slide is moved from Max to Min Delay, or opposite. Continuity between terminal A7 and terminals
A5, A3 and B3 should remain
constant. If not, replace switch.
10. Resistance between terminals A1 and B3 will decrease as the control is moved from Max to
Min Delay, or increase when moved from Min to Max
Delay. If not, replace switch.
11. Place switch in the Lo position, then check for continuity between terminals A4 and B3. If
continuity is not indicated, replace pod switch. 12. Place switch in Hi position, then check for
continuity between terminals A2 and B3. If continuity is not indicated, replace switch. 13. Check for
continuity between terminals B3 and B4, when the front washer button is depressed. If not, replace
switch. 14. Check for continuity between terminals B2 and B5 when the rear wiper switch is in the
On position (indicator lamp will illuminate only when the
headlamps are on). If continuity is not indicated, replace switch.
15. Check continuity between terminals B1 and B5 when the rear washer button is depressed. If
continuity is not indicated, replace the switch. 16. Two switch illuminating bulbs are fed by terminal
B5 (ground) and B6 (power).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams > Diagram Information and Instructions
Washer Fluid Level Switch: Diagram Information and Instructions
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male
and female terminals. A connector identifier is placed next to the arrows to indicate the connector
number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index,
which identifies the connector by number and provides terminal numbering, circuit identification,
wire colors, and functions.
All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.
Splice Location Symbol Identification
Wiring Splice Examples
Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it
(example 1). If there is more than one splice per circuit a small box will be connected to it with the
splice number in it (example 2).
To locate a splice in the wiring harness determine the splice number from the diagrams then refer
to Locations/Splices. This section shows the general location of the splice in the harness.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8846
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.
Fusible Link Color Code
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8847
Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the
event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer
to the fusible link chart for color and gauge identification.
Wire Gauge Color Code Wire Color
12 Ga BK Black
14 Ga RD Red
16 Ga DB Dark Blue
18 Ga GY Gray
20 Ga OR Orange
22 Ga WT White
Main Circuit ID Codes
Main Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8848
International Symbol Identification Chart
Wire Color Codes
Black: BK
Blue: BL
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8849
Washer Fluid Level Switch: Diagnostic Aids
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8850
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 8851
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service
and Repair
Windshield Washer Switch: Service and Repair
The multi-function switch includes the turn signal, headlight beam select and windshield wiper
switches. If any of these switches are found defective, the entire multi-function switch must be
replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3.
On all models, remove upper and lower steering column covers, then remove multi-function switch
tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then
remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
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 (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
Technical Service Bulletin # 818 Date: 990701
Recall - Inadvertent Airbag Deployment
July 1999
Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring
Models
1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service as determined by using the DIAL VIP System.
Subject
The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above
vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately
after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to
inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant.
Repair
A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag
system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve
replacing the clockspring). If the rear wiper motor must be replace.
Alternate Transportation
If inspection determines that clockspring and/or rear wiper motor replacement is required and the
vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by
placing the owner in a loaner vehicle.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8879
Use one of the table labor operation numbers and time allowances shown.
Add the cost of the parts used plus applicable dealer allowance to your claim.
Use the labor operation number and time allowance shown if an owner requires replacement of a
rear wiper motor at some time in the future after the recall has already been completed.
Parts Return
If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be
returned for core credit as quickly as possible using the Mopar Core Return Procedure on your
DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select
Function 10.
If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the
Warranty Material Return Center.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing and material return instructions.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8880
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD818".
Owner Notification and Service Scheduling
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8881
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8882
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner notification letter is included.
Provided with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Parts Information
A. Mastic Patch
Part Number Description
55275444AB Mastic Patch
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Mastic Patches to service about 25% of those vehicles.
B. Clockspring Assembly Package
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8883
Part Number Description
CCXR8181 Clockspring with Speed Control
CCLR8182 Clockspring without Speed Control
Each package contains a clockspring and a mastic patch.
Due to the small number of involved vehicles expected to require clockspring replacement, each
dealer will receive one clockspring for vehicles equipped with speed control. No clockspring
assemblies for vehicles without speed control will be distributed initially. Additional clockspring
packages should be ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require clockspring replacement.
C. Tie Strap/Clips and Heat Shrink Tubing
In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and
ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary.
Additional tie strap/clips and heat shrink tubing may be ordered as necessary.
D. Rear Wiper Motor Assembly
Part Number Description
R4673326 Remanufactured Rear Wiper Motor Assembly
OR
04673326 New Rear Wiper Motor Assembly
Due to the small number of involved vehicles expected to require rear wiper motor replacement, no
wiper motors will be distributed initially. Wiper motors should be ordered only after inspection
determines that replacement is required. Very few vehicles are expected to require rear wiper
motor replacement.
A. Install Mastic Patch & Check For Airbag System
Diagnostic Trouble Codes (DTC's):
1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off.
2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1).
3. Disconnect the liftgate release switch electrical connector (Figure 1).
4. Disconnect the parking hand brake linkage.
5. Set the lower steering column cover aside.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8884
6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure
2).
7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect
the DRB III to the underdash diagnostic connector (blue connector to the right of the steering
column) and power it up.
8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen.
9. Turn the ignition key tot he "ON" position.
10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN
MENU Screen.
12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen.
14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen.
15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen.
16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen.
17. Record all active DTC's for future reference.
18. Press the PAGE BACK key to return to the DTC TYPE Screen.
19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen.
20. Record all stored DTC's for future reference.
21. Press the PAGE BACK key to continue.
22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present).
23. Press the PAGE BACK key to continue.
24. Turn the ignition key off and disconnect the DRB III.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8885
25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the
table. If no airbag system DTC's exist, continue with Step 26.
NOTE:
Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any
airbag system diagnostic trouble codes other than those listed above.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Return the vehicle to the customer. No further action is necessary.
B. Replace Rear Wiper Motor
IMPORTANT:
This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the liftgate wiper arm assembly.
3. Open and raise the liftgate.
4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8886
5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws
(Figure 3).
6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel
screws (Figure 3).
7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3).
8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and
remove the screws (Figure 3).
9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel
(Figure 3).
10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel
from the liftgate.
11. Disconnect the wiper motor electrical connector (Figure 4).
12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor
and bracket assembly from the liftgate and set it aside.
13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate.
Torque the five (5) attaching screws to 35 in-lbs (4 Nm).
14. Connect the wiper motor electrical connector.
15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter
of the panel.
16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3).
CAUTION:
DO NOT over tighten screws as this could damage the trim panel or strip the screws.
17. Install the two (2) screws located in the speaker grille openings (Figure 3).
18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3).
19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3).
20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs.
21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp
assemblies.
22. Close the liftgate.
23. Install the liftgate wiper arm assembly.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8887
24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse
(Fuse # 13) with a new 20 amp fuse (Figure 5).
25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be
repaired, continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Turn the ignition switch to the ON position and exit the vehicle.
31. Connect the negative battery terminal.
32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
C. Repair Driver Airbag Wiring and.or Replace Clockspring
IMPORTANT:
This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble
code.
1. Place the steering wheel in the straight ahead position.
2. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
3. Remove the upper and lower steering column shrouds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8888
4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure
6).
^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5.
^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged,
repair the clockspring wires by taping the damaged area with high quality electrical tape and tie
strap as shown in Figure 6.
^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged,
replace the clockspring assembly as follows:
a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel,
disconnect the airbag module electrical connector and then remove the airbag module from the
steering wheel and set it aside (inflator side down/face up for safety).
b. Disconnect the speed control switch connector (if equipped).
c. Disconnect the horn connector.
d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool
C-3428B), remove the steering wheel.
e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring
pigtail from the steering column.
f. Disconnect the clockspring wiring connector from the back of the clockspring.
g. Unclip the clockspring assembly locating fingers from the steering column and then remove and
discard the clockspring.
h. Snap the new clockspring onto the steering column.
i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring
harness that connects to the ignition switch is between the pigtail and the steering column. Secure
the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6).
j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail
to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA)
(Figure 6).
k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm).
l. Connect the horn connector.
m. Connect the speed control switch connector (if equipped).
n. Connect the airbag module electrical connector and install the airbag module onto the steering
wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm).
5. Install the upper and lower steering column shrouds.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8889
6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the
harness tie strap/clip is secured into the hole (Figure 7).
^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage.
Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert
the clip into the hole.
7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage
to the I/P wiring harness as it routes up past the fuse block (Figure 7).
8. Remove the relay access cover.
9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the
tab off of the fuse/relay/kneeblocker bracket (Figure 8).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert
the clip into the hole.
10. Install another mastic patch to the outboard end of the steel tube that routes the transmission
shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8).
11. Install the relay access cover.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8890
12. Install the lower steering column cover (Figure 1).
13. Connect the liftgate release switch electrical connector (Figure 1).
14. Connect the liftgate release switch electrical connector (Figure 1).
15. Tighten the lower instruments panel cover screws securely.
16. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 9).
17. Slide the cupholder out.
18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9).
19. Slide the console rearward and up to remove.
20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module
(AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8891
21. Install another mastic patch over the rear corner and left edge of the Body Control Module
(BCM) (Figure 10).
22. Install the console assembly.
23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely.
Close the cupholder.
24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely.
25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Turn the ignition switch to the ON position and exit the vehicle.
27. Connect the negative battery terminal.
28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
D. Repair Passenger Airbag Wiring
IMPORTANT:
This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic
trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 11).
3. Slide the cupholder out.
4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11).
5. Slide the console rearward and up to remove.
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6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM)
(Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM)
(Figure 12).
8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness
is installed into the hole on the back side of the left center console bracket (Figure 12).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the
clip into the hole.
9. Install the console assembly.
10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely
(Figure 11). Close the cupholder.
11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely.
12. Disconnect the glove box door check straps and allow the door to open fully.
13. Working through the glove box opening, remove the four (4) screws that attach the passenger
airbag module to the I/P bracket (Figure 13).
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14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad
and lift it away from the snaps (Figure 14).
15. Hold the passenger airbag module door and raise the module from the opening. DO NOT
disconnect the airbag module electrical connectors.
16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any
chafed or cut wires should be repaired per the Wiring Repair.
17. Install a mastic patch on the edge of the passenger airbag module near the electrical
connectors (Figure 15).
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18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical
support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be
repaired per the Wiring Repair Procedure.
19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic
edge cover (Figure 16).
20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50
in-lbs (6 Nm)
21. Connect the glove box door check straps and then close the glove box door.
22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 23.
23. Install the lower steering column cover (Figure 1).
24. Connect the parking hand brake linkage (Figure 1).
25. Connect the liftgate release switch electrical connector (Figure 1).
26. Tighten the lower steering column cover screws securely.
27. Turn the ignition switch to the ON position and exit the vehicle.
28. Connect the negative battery terminal.
29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Wiring Repair Procedure
IMPORTANT:
If airbag system wiring is found chafed or damaged, the wiring should be repaired using the
procedure listed below.
^ If the plastic wire covering is chafed but the wiring strands are NOT damaged:
Tape the damaged area with high quality electrical tape.
^ If the plastic wire covering is chafed and the wiring strands are damaged:
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1. Cut the damaged wire in two.
2. Strip 1 inch of insulation from each end of the wire.
3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire.
4. Spread the strands of the wire apart on both of the exposed wire ends.
5. Push the two wire ends together until the strands of the wire are close to the insulation.
6. Twist the wires together.
7. Solder the connection together using rosin core solder.
8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint
until the tubing is tightly sealed and sealant comes out both ends of the tubing.
9. Secure the wire to the harness to prevent chafing or damage to the insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment
Technical Service Bulletin # 818 Date: 990701
Recall - Inadvertent Airbag Deployment
July 1999
Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring
Models
1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service as determined by using the DIAL VIP System.
Subject
The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above
vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately
after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to
inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant.
Repair
A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag
system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve
replacing the clockspring). If the rear wiper motor must be replace.
Alternate Transportation
If inspection determines that clockspring and/or rear wiper motor replacement is required and the
vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by
placing the owner in a loaner vehicle.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
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Use one of the table labor operation numbers and time allowances shown.
Add the cost of the parts used plus applicable dealer allowance to your claim.
Use the labor operation number and time allowance shown if an owner requires replacement of a
rear wiper motor at some time in the future after the recall has already been completed.
Parts Return
If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be
returned for core credit as quickly as possible using the Mopar Core Return Procedure on your
DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select
Function 10.
If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the
Warranty Material Return Center.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing and material return instructions.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
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DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD818".
Owner Notification and Service Scheduling
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All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner notification letter is included.
Provided with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Parts Information
A. Mastic Patch
Part Number Description
55275444AB Mastic Patch
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Mastic Patches to service about 25% of those vehicles.
B. Clockspring Assembly Package
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Part Number Description
CCXR8181 Clockspring with Speed Control
CCLR8182 Clockspring without Speed Control
Each package contains a clockspring and a mastic patch.
Due to the small number of involved vehicles expected to require clockspring replacement, each
dealer will receive one clockspring for vehicles equipped with speed control. No clockspring
assemblies for vehicles without speed control will be distributed initially. Additional clockspring
packages should be ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require clockspring replacement.
C. Tie Strap/Clips and Heat Shrink Tubing
In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and
ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary.
Additional tie strap/clips and heat shrink tubing may be ordered as necessary.
D. Rear Wiper Motor Assembly
Part Number Description
R4673326 Remanufactured Rear Wiper Motor Assembly
OR
04673326 New Rear Wiper Motor Assembly
Due to the small number of involved vehicles expected to require rear wiper motor replacement, no
wiper motors will be distributed initially. Wiper motors should be ordered only after inspection
determines that replacement is required. Very few vehicles are expected to require rear wiper
motor replacement.
A. Install Mastic Patch & Check For Airbag System
Diagnostic Trouble Codes (DTC's):
1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off.
2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1).
3. Disconnect the liftgate release switch electrical connector (Figure 1).
4. Disconnect the parking hand brake linkage.
5. Set the lower steering column cover aside.
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6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure
2).
7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect
the DRB III to the underdash diagnostic connector (blue connector to the right of the steering
column) and power it up.
8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen.
9. Turn the ignition key tot he "ON" position.
10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN
MENU Screen.
12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU Screen.
13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen.
14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen.
15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen.
16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen.
17. Record all active DTC's for future reference.
18. Press the PAGE BACK key to return to the DTC TYPE Screen.
19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen.
20. Record all stored DTC's for future reference.
21. Press the PAGE BACK key to continue.
22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present).
23. Press the PAGE BACK key to continue.
24. Turn the ignition key off and disconnect the DRB III.
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25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the
table. If no airbag system DTC's exist, continue with Step 26.
NOTE:
Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any
airbag system diagnostic trouble codes other than those listed above.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Return the vehicle to the customer. No further action is necessary.
B. Replace Rear Wiper Motor
IMPORTANT:
This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the liftgate wiper arm assembly.
3. Open and raise the liftgate.
4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3).
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5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws
(Figure 3).
6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel
screws (Figure 3).
7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3).
8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and
remove the screws (Figure 3).
9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel
(Figure 3).
10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel
from the liftgate.
11. Disconnect the wiper motor electrical connector (Figure 4).
12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor
and bracket assembly from the liftgate and set it aside.
13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate.
Torque the five (5) attaching screws to 35 in-lbs (4 Nm).
14. Connect the wiper motor electrical connector.
15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter
of the panel.
16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3).
CAUTION:
DO NOT over tighten screws as this could damage the trim panel or strip the screws.
17. Install the two (2) screws located in the speaker grille openings (Figure 3).
18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3).
19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3).
20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs.
21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp
assemblies.
22. Close the liftgate.
23. Install the liftgate wiper arm assembly.
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24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse
(Fuse # 13) with a new 20 amp fuse (Figure 5).
25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be
repaired, continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Install the lower steering column cover (Figure 1).
27. Connect the parking hand brake linkage.
28. Connect the liftgate release switch electrical connector (Figure 1).
29. Tighten the lower steering column cover screws securely.
30. Turn the ignition switch to the ON position and exit the vehicle.
31. Connect the negative battery terminal.
32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
C. Repair Driver Airbag Wiring and.or Replace Clockspring
IMPORTANT:
This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble
code.
1. Place the steering wheel in the straight ahead position.
2. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
3. Remove the upper and lower steering column shrouds.
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4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure
6).
^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5.
^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged,
repair the clockspring wires by taping the damaged area with high quality electrical tape and tie
strap as shown in Figure 6.
^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged,
replace the clockspring assembly as follows:
a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel,
disconnect the airbag module electrical connector and then remove the airbag module from the
steering wheel and set it aside (inflator side down/face up for safety).
b. Disconnect the speed control switch connector (if equipped).
c. Disconnect the horn connector.
d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool
C-3428B), remove the steering wheel.
e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring
pigtail from the steering column.
f. Disconnect the clockspring wiring connector from the back of the clockspring.
g. Unclip the clockspring assembly locating fingers from the steering column and then remove and
discard the clockspring.
h. Snap the new clockspring onto the steering column.
i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring
harness that connects to the ignition switch is between the pigtail and the steering column. Secure
the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6).
j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail
to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA)
(Figure 6).
k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm).
l. Connect the horn connector.
m. Connect the speed control switch connector (if equipped).
n. Connect the airbag module electrical connector and install the airbag module onto the steering
wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm).
5. Install the upper and lower steering column shrouds.
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6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the
harness tie strap/clip is secured into the hole (Figure 7).
^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage.
Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert
the clip into the hole.
7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage
to the I/P wiring harness as it routes up past the fuse block (Figure 7).
8. Remove the relay access cover.
9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the
tab off of the fuse/relay/kneeblocker bracket (Figure 8).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert
the clip into the hole.
10. Install another mastic patch to the outboard end of the steel tube that routes the transmission
shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8).
11. Install the relay access cover.
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12. Install the lower steering column cover (Figure 1).
13. Connect the liftgate release switch electrical connector (Figure 1).
14. Connect the liftgate release switch electrical connector (Figure 1).
15. Tighten the lower instruments panel cover screws securely.
16. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 9).
17. Slide the cupholder out.
18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9).
19. Slide the console rearward and up to remove.
20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module
(AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
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21. Install another mastic patch over the rear corner and left edge of the Body Control Module
(BCM) (Figure 10).
22. Install the console assembly.
23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely.
Close the cupholder.
24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely.
25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 26.
26. Turn the ignition switch to the ON position and exit the vehicle.
27. Connect the negative battery terminal.
28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
D. Repair Passenger Airbag Wiring
IMPORTANT:
This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic
trouble code.
1. With the ignition switch in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the two (2) screws that attach the lower console to the instrument panel support
brackets (Figure 11).
3. Slide the cupholder out.
4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11).
5. Slide the console rearward and up to remove.
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6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM)
(Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure.
7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM)
(Figure 12).
8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness
is installed into the hole on the back side of the left center console bracket (Figure 12).
^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed
or cut wires should be repaired per the Wiring Repair Procedure.
^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the
clip into the hole.
9. Install the console assembly.
10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely
(Figure 11). Close the cupholder.
11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely.
12. Disconnect the glove box door check straps and allow the door to open fully.
13. Working through the glove box opening, remove the four (4) screws that attach the passenger
airbag module to the I/P bracket (Figure 13).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment >
Page 8915
14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad
and lift it away from the snaps (Figure 14).
15. Hold the passenger airbag module door and raise the module from the opening. DO NOT
disconnect the airbag module electrical connectors.
16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any
chafed or cut wires should be repaired per the Wiring Repair.
17. Install a mastic patch on the edge of the passenger airbag module near the electrical
connectors (Figure 15).
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment >
Page 8916
18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical
support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be
repaired per the Wiring Repair Procedure.
19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic
edge cover (Figure 16).
20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50
in-lbs (6 Nm)
21. Connect the glove box door check straps and then close the glove box door.
22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired,
continue with the appropriate section of the Service Procedure to correct that issue.
^ If no other diagnostic trouble codes require correction, continue with Step 23.
23. Install the lower steering column cover (Figure 1).
24. Connect the parking hand brake linkage (Figure 1).
25. Connect the liftgate release switch electrical connector (Figure 1).
26. Tighten the lower steering column cover screws securely.
27. Turn the ignition switch to the ON position and exit the vehicle.
28. Connect the negative battery terminal.
29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then back to the ON position.
30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Wiring Repair Procedure
IMPORTANT:
If airbag system wiring is found chafed or damaged, the wiring should be repaired using the
procedure listed below.
^ If the plastic wire covering is chafed but the wiring strands are NOT damaged:
Tape the damaged area with high quality electrical tape.
^ If the plastic wire covering is chafed and the wiring strands are damaged:
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment >
Page 8917
1. Cut the damaged wire in two.
2. Strip 1 inch of insulation from each end of the wire.
3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire.
4. Spread the strands of the wire apart on both of the exposed wire ends.
5. Push the two wire ends together until the strands of the wire are close to the insulation.
6. Twist the wires together.
7. Solder the connection together using rosin core solder.
8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint
until the tubing is tightly sealed and sealant comes out both ends of the tubing.
9. Secure the wire to the harness to prevent chafing or damage to the insulation.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 08-07-98 > Mar > 98 > Airbag - Warning Light Illumination
Wiper Motor: All Technical Service Bulletins Airbag - Warning Light Illumination
NO: 08-07-98
GROUP: Electrical
DATE: Mar. 6, 1998
SUBJECT: Airbag Warning Light illumination Caused By A Short in The Rear Wiper Motor/Circuit
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
DISCUSSION:
Some subject vehicles may experience a short in the rear wiper motor/circuit causing fuse # 13 to
blow which illuminates the Airbag Warning light in the instrument panel. When a short in the rear
wiper motor/circuit causes fuse # 13 to blow, the Airbag Warning light is "ON" but the airbag
system still receives power through fuse # 20 and is fully functional, providing the same occupant
protection as when the light is not illuminated. However, when this condition occurs, it hides a
proper warning if an airbag system fault were to occur.
Due to the age of the involved vehicles, some owners may prefer to minimize their expense to turn
off the Airbag Warning light.
For owners seeking a less expensive alternative, if the rear wiper motor itself is the source of the
short, the wiper motor wiring connector can be disconnected and isolated. Then, when fuse # 13 is
replaced, the Airbag Warning light will be extinguished, allowing the Airbag Warning light to
indicate real airbag system faults if they should occur. Use a DRB III to check for any stored airbag
Diagnostic Trouble Codes (DTC's).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiper Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank
Wiper Motor: All Technical Service Bulletins Airbag - Warning Light Illumination
NO: 08-07-98
GROUP: Electrical
DATE: Mar. 6, 1998
SUBJECT: Airbag Warning Light illumination Caused By A Short in The Rear Wiper Motor/Circuit
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European
Market)
DISCUSSION:
Some subject vehicles may experience a short in the rear wiper motor/circuit causing fuse # 13 to
blow which illuminates the Airbag Warning light in the instrument panel. When a short in the rear
wiper motor/circuit causes fuse # 13 to blow, the Airbag Warning light is "ON" but the airbag
system still receives power through fuse # 20 and is fully functional, providing the same occupant
protection as when the light is not illuminated. However, when this condition occurs, it hides a
proper warning if an airbag system fault were to occur.
Due to the age of the involved vehicles, some owners may prefer to minimize their expense to turn
off the Airbag Warning light.
For owners seeking a less expensive alternative, if the rear wiper motor itself is the source of the
short, the wiper motor wiring connector can be disconnected and isolated. Then, when fuse # 13 is
replaced, the Airbag Warning light will be extinguished, allowing the Airbag Warning light to
indicate real airbag system faults if they should occur. Use a DRB III to check for any stored airbag
Diagnostic Trouble Codes (DTC's).
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Page 8927
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Page 8928
Wiper Motor: Testing and Inspection
Fig 9 Liftgate Wiper Motor Electrical Connector
1. Disconnect electrical connector at wiper motor. 2. Place ignition switch in On position, then
check for battery voltage at blue wire. 3. Place wiper switch in On position and check battery
voltage between blue and brown wires. 4. If battery voltage was not present in preceding steps,
proceed as follows:
a. Check fuse, liftgate wiper switch and wiring. b. With ignition switch in On position and wiper
switch in Off position, check for battery voltage between blue and brown wires. If battery
voltage is not present, check ground wire to liftgate switch.
5. If battery voltage was present in preceding steps, replace motor.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Rear Wiper Motor Replacement
Wiper Motor: Service and Repair Rear Wiper Motor Replacement
1. Remove wiper arm, open liftgate and remove trim panel. 2. Remove wiper motor mounting
screws and disconnect electrical connector. 3. Remove motor from liftgate. 4. Reverse procedure
to install. Torque mounting screws to 25-45 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Rear Wiper Motor Replacement > Page 8931
Wiper Motor: Service and Repair Replacement
1. Disconnect battery ground cable, then remove wiper arms. 2. Open hood and remove cowl top
plenum grille, then disconnect wiper fluid hoses. 3. Remove cowl plenum chamber plastic screen,
then the wiper pivot screws. 4. Push pivots down into plenum chamber, then remove nut from wiper
output shaft and linkage assembly. 5. Disconnect wiper motor electrical connector, then remove
wiper motor mounting screw and nuts. 6. Remove wiper motor. 7. Reverse procedure to install,
noting the following:
a. Torque pivot screws, mounting screws and nuts to 5-6 ft. lbs. b. Torque drive crank shaft nut to
7.5-8.5 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams
Wiper Switch: Diagrams
Multi-Function Switch Connector
Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page
8935
Rear Wiper Switch Connector